Work Content Estimation – Multi-Model Assembly Line

February 1, 2024

Work Content Estimation – Multi-Model Assembly Line


mbawankar |

Work Content Estimation - Multi-Model Assembly Line - MODAPTS

Key Points

  • Productivity Improvement by 25%
  • Increased Manpower Utilization to 85%

Client's Challenge

  • Unable to meet orders - long waiting periods
  • Identify true potential capacity of Plant
  • Low Manpower Utilization
  • Inefficient feeding of Sub-Assemblies on Main Line
  • High rejection rates

PMI's Approach

  • Video shooting of all activities on the line
  • Applied MODAPTS indexes on all activities
  • Multi-Model line balancing for a desired TACT
  • Similar steps carried out on Engine Line


  • Improved 25% Productivity on Assembly & 30% on Engine line
  • Manpower utilization rose from 65% to an average of 85%
  • Identification of non-value added work content
  • Provided standardized operations summary sheet

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