January 31, 2024

Capacity Validation Study – TCF


mbawankar |

Automotive TCFCapacity Validation Study

Validating the TCF line to produce target throughput

Key Points

  • Multimodel Assembly line
  • Subassembly line breakdown effect on
  • Throughput improvement roadmap
  • All types of carriers/hangers (10 types) optimized; outcome used for purchasing

Client's Challenge

  • Effect of introduction of new models
  • Amount of blockage in the system due to downtimes
  • Optimum number of carriers
  • Buffer/ Decoupler capacity

PMI's Approach

  • Analysis of Data, building the model, and verification
  • Analysis of baseline model results
  • Buffer Sensitivity Analysis for some parts of the Chassis
  • Carrier optimization for every subassembly
  • What-Ifs to reach standard uptime

Findings & Recommendation

  • Model was found to fall short of achieving the target
  • Number of extra fuel fill equipment determined to reach
    desired uptime at Flattop
  • De-couplers before and after Chassis line 6 were identified as the
  • What-ifs conducted to find options to meet targets

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