Engagement Start : 2018
Location : Dharwad
Scope : Jig, Dropping & Coupling Area for LCV, MCV, and EV Buses
The Challenge
One of our Clients, a leader in manufacturing LCV, MCV, and EV buses, faced the challenge of maintaining 100% production delivery despite fluctuating demand, varying model mixes, and seasonal shifts in production volumes. The focus was on ensuring dimensional accuracy, minimal downtime, and efficient production lines – while maintaining the highest standards of safety and quality.
The Layam Solution
Since 2018, Layam Group has been a key partner in streamlining Our Clientʼs production operations in the Jig, Dropping, and Coupling areas. Our approach involved a data-driven strategy – from production and downtime reports to continuous skill development and process optimization
Key Deliverables
- Real-time MIS Reports on Production & Downtime
- Attendance and Absenteeism Monitoring for seamless operations
- Yearly Upskilling of Welders and skilled workforce for operational excellence
- Customer Concern Reports (HPCC) to address production issues proactively
- Kaizen-based Process Improvements with actionable work instructions and feedback loops
The Process that Drives Excellence
Production & Downtime Monitoring
- Daily MIS reports provide real-time insights into production status and downtime
- HPCC Production Loss Analysis to identify bottlenecks and root causes of delays
- Continuous feedback loops to improve line performance
Skill Development & Upskilling
- Welding skill upgradation for associates every year, ensuring technical proficiency
- Job rotation practices to build a multi-skilled workforce that adapts to varying production needs
Systematic Process Improvements
- Work Instructions and Kaizen sheets to drive efficiency across the production line
- Implementation of "Doʼs and Donʼts" for standardization and process control
- Root-cause analysis and PDCA (Plan-Do-Check-Act) to prevent production delays and defects
Results & Impact
- 100% Productivity Delivery : Consistent output even with fluctuations in model mix and volume
- Zero Incidents/Accidents : Robust 5S system implementation and adherence to safety norms
- Dimensional Accuracy & Quality Control : Build-in quality checks leading to reduced defects per vehicle (DPV)
- Enhanced Workforce Skills : Annual upskilling initiatives, ensuring a more versatile workforce
- Line Efficiency Improvements : Proactive, data-driven approach to boost production line performance by 15%
Why It Matters?
At Layam, we focus on creating a synergistic partnership where workforce solutions are directly aligned with your operational goals. For Our Client, our collaborative approach ensured that production was not just timely, but also efficient and error-free.
