Industrial EngineeringCompleted
2026
Industrial Engineering - Based Productivity & Layout Optimization: A Case Study
Individual Project - Asiri Sandakelum
Layout Optimization
Productivity Improvement
Process Mapping
Inventory Strategy
01 — Overview
Optimized assembly and inspection processes at the Hero Motorcycle Assembly Plant using facility layout improvements, material handling reduction, and safety-focused test track design.
02 — Problem Statement
Suboptimal layout, bidirectional movement paths, shared-road testing, and reactive WIP management limited throughput and raised safety risks.
03 — Objectives
- 01Optimize assembly and inspection flow for higher plant productivity
- 02Reduce material handling waste and eliminate dead-end workstations
- 03Establish a dedicated drive-through test track and safer workflow
- 04Implement strategic safety stock to reduce WIP delays
04 — Key Outcomes
Identified PDI/QC as primary constraints with 75 minutes/unit
Reduced material search waste by 90 minutes per batch
Proposed a drive-through workstation layout and standalone test track
Developed a data-driven inventory strategy for stable throughput
05 — Tools & Technologies
Shop-floor observationProcess MappingLayout OptimizationInventory Strategy