Introduction
When it comes to automobile manufacturing, the Trim, Chassis, and Final (TCF) line is where components converge and complexity peaks. For a leading vehicle manufacturer planning the integration of multiple new models into its multi-model TCF assembly line, the challenge wasn’t just to keep pace, it was to predict performance, minimize downtime disruptions, and make informed equipment purchase decisions. To ensure the system could withstand real-world variability and deliver the required throughput, the client turned to Production Modeling India (PMI) for a comprehensive capacity validation study.
Client’s Challenge
- Understand the impact of introducing new vehicle models on system flow
- Quantify the effect of subassembly breakdowns on the mainline
- Determine the optimal number of carriers and hangers across 10 different types
- Identify the ideal buffer and decoupler capacities to prevent system blockage
- Establish a throughput improvement roadmap while staying within capital constraints
Optimizing Throughput and Carrier Allocation in a Complex TCF Assembly Line - A Case Study
PMI’s Approach
PMI adopted a simulation-led strategy with a multi-phase model:
Baseline Model Development & Validation
Built a data-driven digital model of the TCF system using real process flows, cycle times, and downtime records.
Buffer and Carrier Optimization
Conducted buffer sensitivity analysis for critical parts of the Chassis line and optimized carrier counts for each subassembly station.
What-If Scenario Testing
Simulated various downtime and uptime conditions, identifying how equipment availability and layout changes could improve overall performance.
Bottleneck Identification
Deployed WIP and time-in-state tracking to pinpoint congestion zones—particularly around de-couplers before and after Chassis Line 6.
Findings & Recommendations
• The system was not meeting the target throughput under current configurations.
• Additional fuel fill equipment was required at the Flattop station to ensure reliable uptime.
• De-couplers near Chassis Line 6 were acting as the primary bottlenecks.
• What-if experiments guided a data-backed roadmap for reaching target performance.
• Carrier and hanger optimization outcomes were used to inform procurement—preventing over- or under-purchasing.
Optimizing Throughput and Carrier Allocation in a Complex TCF Assembly Line - A Case Study
Conclusion
By combining simulation with operational insight, PMI enables the client to move from reactive adjustments to proactive, precision-driven decisions—ensuring the TCF line is future-ready, flexible, and built to deliver.