Introduction
In fast-paced manufacturing environments, every second counts. When unnoticed inefficiencies pile up across processes like welding and fitting, the impact can be significant—lost time, underutilized resources, and missed targets. Recognizing the need for a data-backed approach, a leading fabrication unit approached Production Modeling India (PMI) to conduct a Resource Utilization and Loss Time Analysis Study. The goal? To quantify time losses, standardize work content, and prepare a proactive planning template for upcoming production batches.
Client’s Challenge
• Need to measure work content for current and upcoming products
• Inability to quantify losses and non-value-added (NVA) time effectively
• Requirement for a template-based system for planning future production timelines and manpower
Production Study Reveals 40% NVA Time, Enabling Smarter Resource Planning - A Case Study
PMI’s Approach
PMI executed a structured study that merged real-time observation with analytical modeling:
Key welding and fitting operations were mapped across fabrication areas.
A customized loss observation format was used to record idle time, delays, and inefficiencies.
Repetitive processes were captured and analyzed to extract cycle times and pinpoint NVA activities.
Each process was broken down into value-added (VA) and non-value-added (NVA) components to assess true efficiency.
Standardized time data was used to build a work content planning template applicable to both current and new products.
Results & Impact
• Resource utilization levels were mapped accurately across operations.
• About 40% of NVA time was identified with actionable suggestions for reduction.
• A standard work content template was created, enabling advance estimation of time for welding and fitting tasks.
• The client gained a repeatable framework for continuous improvement and production planning.
Conclusion
PMI’s intervention transformed assumptions into insight. By quantifying hidden inefficiencies and providing a structured approach to planning, the client is now equipped to achieve better productivity, tighter timelines, and smarter use of manpower and machines.