Manufacturing Case Studies
Explore real shopfloor engagements across automotive, steel, foundry, packaging, precision engineering, and heavy manufacturing sectors. See how we solve bottlenecks and drive operational performance.
Assembly Line Balancing & Layout Optimisation
Uneven work allocation across 14 sub-assembly stations caused severe line starvation, operator idle time, and low daily throughput.
- •Conducted Current State Value Stream Mapping (VSM) and Line Balance Audit
- •Executed MOST (Maynard Operation Sequence Technique) time-and-motion studies
- •Created Spaghetti Diagrams to track operator travel routes and material movement
Plate Mill Capacity Optimisation
Severe throughput bottlenecks at plate shearing lines and uncoordinated reheating schedules restricted total plant volume.
- •Executed End-to-End Material Velocity and Bottleneck Capacity Audit
- •Applied Theory of Constraints (TOC) to identify physical plant bottlenecks
- •Modeled Drum-Buffer-Rope (DBR) schedule for furnace heating and rolling
OEE & Quick Changeover Optimisation
High-runner extrusion film lines lost 12+ hours per die changeover due to disorganized tool preparation and unstandardized procedures.
- •Conducted video SMED (Single-Minute Exchange of Die) audit of changeover steps
- •Categorized changeover tasks into internal (machine stopped) and external (machine running) elements
- •Converted internal die pre-heating tasks into external prep activities
Workforce Productivity Improvement
Heavy casting foundry suffered from high contract headcount dependency, manual flask handling delays, and poor spatial layout.
- •Executed Day-In-The-Life-Of (DILO) studies for moulding crews and furnace teams
- •Mapped worker travel paths and ergonomics using motion economy principles
- •Designed low-cost pneumatic hoists and gravity chutes for flask handling (LCIA)
CNC Setup & Spindle Optimisation
Custom machining shop lost 35% of CNC machine capacity to batch setup delays, fixture zero-setting, and CMM inspection waits.
- •Conducted setup time analysis across high-precision CNC machining centers
- •Introduced zero-point modular quick-clamping fixtures for instant part location
- •Established offline tool presetting routines to prepare tooling before machine stops
Fabrication Layout & Lead Time Optimisation
Heavy structural fabrication facility suffered from crisscrossing overhead crane movements, beam backtracking, and congested welding bays.
- •Created detailed Spaghetti Diagrams tracking overhead crane and plate movement
- •Analyzed structural steel fabrication steps from cutting to final welding
- •Designed a unidirectional linear flow layout from plate cutting to dispatch
How Do We Deliver These Operational Results?
We follow our 5-phase transformation framework (Diagnose, Analyse, Design, Execute, Sustain) to ensure that improvements are locked in permanently.