Layout Design and Industrial Engineering Study for DG Set Engine Assembly Plant

February 1, 2024

Layout Design and Industrial Engineering Study for DG Set Engine Assembly Plant


mbawankar |

Key Points

  • Shifting of assembly to a new location
  • New Shop floor Layout Designing
  • Production Capacity ramp-up
  • Work measurement using PMTS of all the assembly activity

Client's Challenge

  • Layout designing with incorporating multiple parameters

  • Multi-model Balancing of the assembly lines

PMI's Approach

  • Existing facility go through and understanding process flow
  • Bottleneck Identification
  • Data Collection for Work Measurement
  • Data Collection for layout design
  • Layout Options Preparation and Discussion
  • Layout Marking on shop floor
  • Elemental Details Preparation
  • Preliminary Analysis Report Preparation

Layout Options & Comparisons

Final CAD Layout

Comparison - Existing vs Proposed

Existing vs Proposed Line Balancing


1. Use of Powered Conveyors to

  • Elevate manpower utilization by eliminating manpower dependencies
  • Smooth Engine Movement on conveyor without Manpower Interruption

2. To further increase in production,

  • Increase in length of oven is recommended
  • Automation for coolant and water filling in radiator to reduce cycle time

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