Lean Analysis, Productivity Improvement

A heavy machinery manufacturer approached ARi to provide a line optimization report for their engine assembly area.

Project Scope

A heavy machinery manufacturer approached ARi to provide a line optimization report for their engine assembly area.

Business Challenges

To capture the gap between Capacity Vs Actual in workstations.

ARi’s Solutions

By capturing the non-value-added activities through video analysis of the existing build scenarios, the team improved build time at each workstation. The video analysis provided necessary information to segregate the assembly activities into 3 categories as per lean principles with the help of the Timerpro Tool. The team classified the activities into “Value Added”, “Non-Value Added”, and “Required Non- Value Added” throughout the cycle time of each activity. On completion of classification of activities, the team generated the report with suggested solutions to eliminate the wastes in the assembly line.

ARi’s Value Proposition

Through the time-study and suggestions, the team was able to balance the assembly line by avoiding bottlenecks and minimizing the non-value-added activities resulting in value-added solutions leading to reduced waste to 33% from 91%.