Productivity improvements in oil pumps assembly & testing

Project initiation date: 07/12

Challenge

NTBC oil pump (Cummins) requirement increased from 500nos. to 1800nos. per month. Assembly & testing is the identified system constraint. Existing productivity of assembly & testing was 18 & 38 nos. per shift respectively. To meet the increased demand, it was needed to increase the capacity of assembly & testing. Since management policy does not allow to increase manpower, without increase in productivity (without fully exploiting the constraint). Capacity addition without improving productivity would have increased the cost of manpower, other expenses like power bill & other overheads. This would reduced bottom line.