Project Description

Overview

This case study focuses on a leading commercial vehicle manufacturer. Holisol Logistics was tasked with managing in-plant line feeding and PPC (Production-Planning-Control) operations at their Ennore facilities.

    • Volume/Day: 120 Commercial Vehicles
    • On-Roll Employees: 35+
    • Off-Roll Employees: 300+
    • Shifts/Day: 3

The Challenge

Our customer faced significant operational challenges with their previous logistics service provider:

    • Ineffective Employee Management: Poor handling of on-roll and off-roll employees led to low attendance and morale.
    • Lack of Operational Improvements: No substantial enhancements in shop floor efficiency or workflow for over a year.
    • Impact on Production: These inefficiencies directly affected production output and customer satisfaction.

Why Holisol?

We were selected for our proven ability to efficiently manage complex in-plant and line feeding operations.

    • Proven Track Record: Successful execution of SKD projects.
    • Cross-Industry Expertise: Experience in agriculture, construction, and automotive sectors.
    • Rapid Operational Turnaround: Ability to implement swift improvements.
    • Flexibility to Meet Urgent Requirements: Adaptable solutions tailored to immediate needs.

Our Solution:

To address these challenges, we implemented a comprehensive approach:

    • In-Plant Line Feeding: Established dedicated teams for critical areas such as Axle, Engine Dressing, Chassis, and Gear Box, ensuring timely material delivery and strict adherence to PPC schedules.
    • Effective Manpower Management: Deployed experienced plant heads and HR managers to oversee over 160 personnel across three shifts, achieving 95% attendance and preventing line stoppages.
    • Performance Monitoring: Set up a daily MIS reporting system to track KPIs, enabling quick responses to discrepancies and alignment with the customer’s operational goals.

Our Services:

We provided a range of services designed to optimize workflow and improve the performance.

    • PPC Plan Adherence: Implemented effective production planning and control.
    • Line Feeding & Material Handling: Managed kitting, sequencing, and timely delivery from the Super Market to the production line.
    • Quality Control: Conducted quantity and variant checks to ensure standard packaging adherence.
    • Parts Management: Specialized in feeding for axle and engine dressing parts, maintaining optimal material availability.
    • Efficiency Measures: Applied 5S practices and SAP-triggered shortage alerts to enhance operational efficiency.
    • Inventory Management: Coordinated ZV parts replenishment and handled reverse logistics for empty components.
    • Reporting: Maintained regular stock updates and shift-end MIS reporting for operational transparency.

The Results:

    • Zero Line Stoppages: Achieved uninterrupted operations, ensuring consistent production.
    • 95% Employee Attendance: Maintained high attendance levels even during challenging periods.
    • Streamlined Efficiency: Enhanced operational flow with precise PPC adherence and material management.
    • Future-Ready Enhancements: Set to implement advanced PPC and line feeding solutions by October 2024.

Interested in learning more about this case study or our commercial vehicle packaging and logistics solutions? Connect with our domain expert, Ashish Sharma, at [email protected].