...

Streamlining Capacity and Resources Optimization in Agriculture Machinery/Equipment Manufacturing Industry

PMI > Blog draft > Case Study > Streamlining Capacity and Resources Optimization in Agriculture Machinery/Equipment Manufacturing Industry

Introduction

Farmers are no longer concerned about soil and seeds anymore, it's now about strategy, precision, and timely action. And the equipment that backs farmers is instrumental in this revolution. This case study traces the path of an innovative agri-equipment company with a vision to empower Indian farmers through cost-effective mechanization. The firm, with strong roots in its social vision, wanted to expand operations and productivity while keeping costs and complexity at bay.

With production requirements increasing and an objective to raise daily output from a half unit to up to three units, the customer approached Production Modeling India (PMI). The objective? Reimagine processes, streamline manpower, and release latent capacity through the application of scientific industrial engineering techniques.

Client Objectives and Scope

The client's main concern was evident: rationalize production in pre-painting, painting, and post-painting zones and get the facility ready to grow capacity for the future. The overall goals were:

• Optimization of manpower to enhance utilization levels from a mere 45% to an optimal 85%.
• In-depth capacity extension study to facilitate production scenarios of 1, 2, and 3 units per day.
• Proper resource calculation based on PMTS (Predetermined Motion Time System) methods.
• Identification and removal of non-value-added (NVA) and essential non-value-added (E-NVA) activities.
• Suggesting layout changes and action plans to facilitate long-term expansion.

Challenges Encountered

Although the client possessed the vision and potential, they were confronted with a number of on-ground challenges:

  • Boosting production without significantly increasing cost or sacrificing quality.
  • Inefficient manpower utilization, with redundant movement and rework creating inefficiencies.
  • A paint shop layout that did not facilitate scaled operations or seamless flow.
  • Lack of real-time, systematic data for making informed decisions.
  • Difficulty in visualizing the impact of layout and manpower changes for different production targets.

Streamlining Capacity and Resources Optimization in Agriculture Machinery/Equipment Manufacturing Industry

Download Case Study PDF

PMI’s Strategic 3-Stage Approach

PMI designed a robust, three-phase intervention that combined observation, analysis, and simulation to guide decision-making.

1. Data Collection

PMI’s team, including one project manager and three engineers, visited the site to gather ground-level insights. This phase involved:

• Video recording of activities in the pre-painting, painting, and post-painting sections
• Tight contact with the client's Cross Functional Team to confirm current workflows
• Watching machine-directed and manual activities to identify actual work content

Excel Simulation for Pre-Painting:

2. Data Analysis and Estimation

This step constituted the foundation of the research:

• Activities were decomposed through PMTS methods to determine manual and machine cycle times.
• Work content forms were developed and confirmed with the client's Cross Functional Team (CFT).
• Time was divided into value-added, non-value-added, and necessary non-value-added segments.
• Excel-based simulations and stage balancing were employed to graph output capability on 1/day, 2/day, and 3/day production schedules.
• Optimization insights were given through line balancing and resource planning models.

Streamlining Capacity and Resources Optimization in Agriculture Machinery/Equipment Manufacturing Industry

Download Case Study PDF

Findings and Recommendations

The findings were not only instructive; they were revolutionary:

• With the existing layout and workflow, a production target of 1 unit/day was possible with minimal adjustments and rework minimization, as long as two shifts were utilized.
• For 2/day and 3/day production, modifications to the paint booths were required to remove bottlenecks and allow for uninterrupted flow.
• Hypothetical layouts for each production mode were created with unobstructed pathways, minimized movement, and effective equipment location.
• Manpower utilization was significantly improved, with maximum deployment in shifts and tasks.
• PMI also offered a preliminary CAPEX sheet for the client's effective planning of plant modifications.

Conclusion

This study indicates how farm machinery manufacturing, tended to be motivated by legacy technology, can gain significantly from industrial engineering that is backed by data. PMI's intervention allowed the client to switch from guessing to accuracy, allowing them to plan for size without compromising cost control or flow of operations.

Through re-engineering their strategy towards manpower, layout, and resource planning, the organization is now well-positioned not just to address today's needs but to grow with confidence, enabling Indian farmers one solid machine at a time.

Related Case Studies

Indirect Area Study in Tyre Manufacturing Industry

Transforming Electrical Soft Ferrite Core Manufacturing Industry through IE Study

Productivity Improvement in Agricultural Equipment Manufacturing Industry

Stopwatch Time Study Enhances Efficiency and Production for a Prominent Bike Manufacturer in India

Optimizing Aeronautical Operations Efficiency with Time and Motion Study

Work Content Measurement and Process Improvement in a BOPP Film Manufacturing Plant Using PMTS Techniques

    Download Our Company Brochure