Productivity Improvement in Agricultural Equipment Manufacturing Industry
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This case study highlights a leading Agricultural Equipment manufacturer with a vision to lead global innovation. Objectives encompassed work analysis through PMTS, line balancing, optimizing manpower distribution, calculating machine utilization, and resource allocation. The study's focal point was Value-Added and Non-Value-Added analysis. The client aimed for efficiency, elevating their potential to revolutionize agriculture products on a global scale.
Key Points
For Existing Production capacity of 3000 units per month
- Productivity improvement by 49.7%.
- Manpower reduction by 33.2%
For Proposed Production capacity of 4500 units per month
- Productivity improvement by 67.3%.
- Manpower reduction by 40.2%
Client's Challenge
- Reduction in manpower fatigue.
- Dashboards for production planning as per demand.
- VA/NVA analysis for further improvement.
- Identify true potential capacity of plant.
- Low manpower utilization.
- Layout Modification
- Low-Cost Automation
PMI's Approach
The study was organized in a 3-stage process:
- Data Collection - Video shooting of all activities on the line.
- Estimation & Data Analysis – Basic MOST estimation, work distribution, dashboard preparation, VA/NVA analysis.
- Results and Conclusion – Dashboards for future planning, fatigue reduction, improved productivity, improved manpower utilization, identification of NVA work content.
Involvement of Associates –
- PMI – 1 Project Manager, 2 Engineers.
- Client – 2 Project Co-ordinators.
Data Collection:
- Recording videos by PMI Engineers.
- Interaction with client to understand process.
- Production Data for last 6 month.
Data Analysis:
- Preparation of elemental details using PMTS technique & validation by client.
- Analysis (Work distribution/VA-NVA identification) for manpower calculation, optimum manpower utilization & identifying capacity.
- Dashboard preparation for production planning as per demand.
- Improvement & suggestions for fatigue reduction & making existing system better.
Results & Conclusion
After doing analysis and evaluation following results were obtained –
- Improved productivity by 67.3%.
- Fatigue reduction by rotation of operators in between lines & by introducing low-cost automation.
- Dashboards for future planning as per demand & as per working lines.
Overall Summary Dashboard
- Improvement and Suggestions
-
- Special fixtures suggested wherever necessary to reduce the dependency of extra manpower to hold the work piece.
- General improvements such as special markings for inventory level to be incorporated, oil dispensers to be available at required locations, etc.
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