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| S. No. | Name of shop | Proposed action | Non-value-added activity | Suggested smart production management system | Process optimization |
|
| 1. | Transmission | (i) Reduced distance between workstations | Transportation, inventory, motion, non-utilized talent | Automated production line | Yes |
| (ii) Machinery placed at the planned location |
| (iii) Provide material handling equipment |
| (iv) Followed up safety norms on the shop floor |
| (v) The workload has been decided according to the skill of the workers |
|
| 2. | Fabrication | (i) Decided workload according to the skill of the workers | Non-utilized talent, motion, waiting, defect | Embedded system | Yes |
| (ii) Reduced number of workstations |
| (iii) Developed fabrication planning |
| (iv) Arranged fabrication equipment in a systematic manner |
|
| 3. | Profile cutting | (i) Organized training for operators | Non-utilized talent, motion | Embedded system | NA |
| (ii) Eliminate unnecessary activities |
|
| 4. | Engine assembly | (i) Improvement in layout | Transportation, inventory, motion, non-utilized talent, excess processing | Automated production line | Yes |
| (ii) Reduced distance between workstations |
| (iii) Increased number of workers |
| (iv) Arranged material handling equipment in a proper manner |
|
| 5. | Painting | (i) Increased number of workers | Motion, waiting, overproduction | Embedded system | Yes |
| (ii) Provided safety equipment for workers |
| (iii) Both the processes were started simultaneously |
|
| 6. | Hot testing | (i) Decided timeline on the workstation | Motion | Embedded system, asset tracking system | Yes |
| (ii) Increased shop floor area in layout |
|
| 7. | Cabin installment | (i) Organized meetings and training | Excess processing, motion | Automated production line, embedded system | Yes |
| 8. | Electric gauge assembly | (i) Replaced operator by skilled operator | Excess processing, non-utilized talent, inventory | Embedded system | Yes |
| (ii) Decided workload distribution |
|
| 9. | Quality inspection | (i) Improve production planning | Motion, excess processing | Automated production line | Yes |
| (ii) Eliminate unnecessary activities |
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