Case Study :

Cycle Time Improvement

Cycle Time improved by 13% and Production improved by 6%

Cycle Time Improvement

Client Summary :

The client is involved in the
manufacturing of wheels for light
motor vehicles and heavy vehicle
industries. They produce up to four
million wheels per year for global
vehicle manufacturers such as Ford,
General Motors, Honda, Hyundai-Kia,
Nissan, and VW.

Industry:

Automotive Component Manufacturing
Industry

Challenges:

Improving the cycle time of overall machines in the welding line
without affecting quality and safety involved in wheel manufacturing.

Improvement Observed:

13% improvement in the new cycle time data compared to the old cycle time.
Optimized the speed of operation of the Coiler, Welder Loader, and Swing Arm.
Increased speed of operation between the SW1 and Welder Loader by reducing
the operating distance between them, leading to increased productivity.
Significant improvement (~30%) observed in the average cycle time, reducing from 8.87 seconds to 7.11 seconds.
Standard deviation of overall cycle time improved from 64% to 38%.

Customer Feedback:
“Our wheel production has surged by 6%, and the 13% improvement in cycle time
has streamlined our operations like never before. The impact on our efficiency
and output is remarkable—this has truly transformed our manufacturing process!”

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