Industrial Engineering
Transform complex production environments into streamlined, measurable and scalable systems
Time Studies (MODAPTS / MTM / MOST)
Establish precise time standards using globally certified methodology.
Line Balancing
Distribute workload across stations to consistently hit target JPH.
Capacity Planning
Analyse production capacity against current and future demand.
Lean Manufacturing
Systematically identify and eliminate waste across your production system.
Vehicle Benchmarking
Compare competitor vehicles against your own design and quality standards.
AI Time Studies (POC)
AI-assisted video analysis to automate motion recognition and classification.
Time Studies (MODAPTS / MTM / MOST)
Establish accurate time standards for every assembly operation using internationally certified Pre-Determined Motion Time Systems (PMTS).
CY4's MODAPTS-certified team analyses every micro-motion, providing a scientific, defensible basis for all capacity planning, line balancing and operational efficiency decisions.
Deliverables
- MODAPTS / MTM / MOST time study for every assembly operation
- Station-level to plant-level time standards, aggregated into full production model
- Identification of Non-Added Value (NA) and Non-Value Added But Necessary (NVABN) activities
- Time study documentation: operator-level, station-level and line-level reports
- Input for line balancing, capacity planning and productivity improvement programmes
Use Case / Client Example
Daimler Trucks needed certified MODAPTS time standards for a new 38-station truck assembly line. CY4's MODAPTS-certified team conducted on-site time studies and delivered plant-level time standards within 6 weeks, revealing 14% of operator time was NVABN waste. Addressing these identified savings of ₹1.2 Cr per year in direct labour cost.
Line Balancing & Capacity Planning
Eliminate idle time, hit your JPH target and model your growth with confidence.
Line balancing optimises workload distribution across assembly stations to eliminate idle time, reduce cycle time and consistently hit target jobs-per-hour without adding resources. Capacity planning analyses your production system against current and future demand, identifying constraints before they limit your output.
Deliverables
- Balanced line chart: work content per station vs takt time
- Cycle time analysis and jobs-per-hour (JPH) validation against production targets
- Workforce optimisation: minimum operator count to achieve target with balanced load
- Capacity gap analysis: current vs required capacity against demand forecast
- Expansion scenario modelling: impact of additional shifts, stations or headcount
Use Case / Client Example
A Tier 1 steering systems supplier needed to increase output from 180 to 240 units/shift without adding a new line. CY4's line balancing analysis identified 3 overloaded stations and 4 stations with significant idle time. Rebalancing the 18-station line achieved 235 units/shift, 98% of target, with zero new headcount and zero capital investment.
Lean Manufacturing & Vehicle Benchmarking
Eliminate waste systematically. Benchmark globally to raise your quality standard.
Lean Manufacturing: CY4 applies Value Stream Mapping, 5S, Kaizen and standard work to systematically identify and eliminate all forms of waste across your production system, delivering measurable, sustainable efficiency improvements. Vehicle Benchmarking: Benchmark competitor or reference vehicles against your own design and assembly standards, analysing build quality, assembly complexity and cost drivers to identify best practices.
Deliverables
- Value Stream Map (VSM): current and future state with quantified improvement potential
- Waste walk and identification report: 7 waste categories mapped to production floor
- Standard work and 5S implementation, documented and trained
- Vehicle benchmarking report: quality gap analysis vs nominated reference vehicles
- Assembly complexity comparison and cost driver breakdown
Use Case / Client Example
Ather Energy benchmarked their EV scooter assembly process against a leading competitor's vehicle. CY4 conducted a full physical teardown and assembly complexity analysis, identifying 11 components where the competitor's design required 40% fewer fasteners. These findings directly influenced Ather's next-generation product DFA brief.