Major Automotive Original Equipment Manufacturer (OEM)
Efficiency Improvement in Assembly Line Operations
Optimizing assembly line processes is essential to reducing costs and increasing productivity
Optimizing assembly line processes is essential to reducing costs and increasing productivity. Ingenics consultants, specializing in industrial optimization, conducted a workshop focused on improving efficiency in assembly line operations. The aim of this workshop was to analyze and enhance process time, optimize resource utilization, and improve overall productivity within the assembly and pre-assembly lines.

The efficiency improvement workshop led to the following significant results:
1. Optimized Production Process:
The production process was significantly optimized through the use of MTM calculations and systematic workload analysis.
2. Increased Productivity:
Productivity increased by 25%, due to the elimination of waste and streamlined processes. Additionally, a personal savings of 10 employees per shift was achieved.
3. Efficiency Improvement:
The project resulted in an overall efficiency improvement of 14%, enhancing the line's ability to meet production targets with fewer resources.
Objective
- Cost Reduction: By eliminating inefficiencies in the process, Ingenics aimed to reduce production costs.
- Productivity Improvement: Increase productivity through optimized workflows and reduced process time.
- Process Optimization: Address low quality of process time in the company production system, an issue identified during the initial assessment.
Approach
To achieve these goals, Ingenics followed a structured approach focused on analysis, optimization, and implementation:
1. AS-IS Analysis:
A thorough examination of the existing processes was conducted to assess inefficiencies and identify areas for improvement.
2. Time Analysis (MTM):
The team performed a detailed time analysis using the MTM (Methods-Time Measurement) system to calculate standard times and evaluate process inefficiencies.
3. Optimization of Work Area and Material Zone:
The working area and material zones were redesigned to enhance workflow, reduce movement, and minimize waiting times.
4. Updating Company Production System:
The company's process planning tool was updated to ensure that time data was accurate, eliminating discrepancies and providing better insights into process performance.
5. CIP (Continuous Improvement Process) Workshops:
Workshops were conducted with assembly line teams to discuss and implement improvement ideas, focusing on streamlining operations and addressing specific issues.
6. Conceptual Design and Action Plans:
Ingenics developed conceptual designs for process improvements and created detailed action plans for implementation.
7. Coaching Employees:
Employees were trained in key methods, including time study techniques, the MTM system, and other best practices to ensure long-term success.
8. Implementation Support:
Ingenics provided support during the implementation of the changes, monitoring progress and ensuring the adjustments were properly executed.
9. Documentation and Reporting:
All results, including changes to the process, time values, and performance metrics, were carefully documented to support ongoing improvements and to inform global operations.
Results
The efficiency improvement workshop led to the following significant results:
1. Optimized Production Process:
The production process was significantly optimized through the use of MTM calculations and systematic workload analysis.
2. Increased Productivity:
Productivity increased by 25%, due to the elimination of waste and streamlined processes. Additionally, a personal savings of 10 employees per shift was achieved.
3. Efficiency Improvement:
The project resulted in an overall efficiency improvement of 14%, enhancing the line's ability to meet production targets with fewer resources.
5. Cleaned Up Time Values in Production System:
The system was updated to reflect more accurate time values, ensuring better planning and forecasting for future production runs.
6. Documentation of Potential Optimizations:
Ingenics conducted a "deep dive" into potential global optimizations, documenting strategies that could be used in automotive plants worldwide.
Summary of Realizations
This workshop demonstrated the importance of thorough analysis, process optimization, and employee involvement in achieving significant efficiency gains on the assembly line. Ingenics' systematic approach delivered measurable improvements in productivity, reduced labor costs, and helped to identify long-term strategies for global optimization in automotive manufacturing. By combining the latest time analysis methods, such as MTM, with strategic redesign of workflows, Ingenics was able to contribute to substantial cost savings and performance enhancement for the client.
This project serves as an example of how targeted interventions and continuous improvement processes can lead to enhanced operational efficiency in the automotive industry.