Streamlining Your Shop Floor: How Material Flow Simulation Drives Operational Efficiency

In today’s competitive automotive landscape, optimizing inventory at storage areas and on the line, along with inbound and outbound logistics, is essential for success. Production delays, testing bottlenecks, and suboptimal space utilization not only impede operational efficiency but also lead to increased costs. To overcome these challenges, Hinduja Tech utilizes advanced material flow simulation to help manufacturers optimize their plant operations, making logistics smarter, processes faster, and investments more impactful.

The Challenge

Modern manufacturing involves balancing multiple constraints in material flow, from raw material to finished goods. Hinduja Tech’s recent project illustrates the complexity of optimizing plant operations and capacity planning. With three production lines feeding two roll-test stations operating under different takt times, the objectives were clear yet challenging:

• Optimize parking capacity for trucks arriving after roll-test stations
• Synchronize production lines converging on limited roll-test capacity
• Manage increasing roll-test demands without creating backlogs
• Conduct spatial analysis of offline areas and truck parking zones
• Identify critical bottlenecks impacting inventory flow between End-of-Line (EOL), test areas, and finished vehicle storage

Without the right insights and planning, achieving these objectives would have been difficult, risking longer cycle times, inventory pileups, and production slowdowns.

Advanced Simulation for Smart Solutions

Hinduja Tech utilizes plant simulation tools to validate, digitally model, and test operational scenarios before implementing any physical changes. By running “what-if” analyses, the team assessed impacts on Tecnomatix Plant Simulation tool throughput, space, and timing, avoiding costly trial errors on the shop floor.

The simulation approach involved:

• Validating production and testing sequences digitally
• Modelling takt time variations and capacity limits
• Analysing inventory levels between key stages
• Optimizing offline spaces for truck parking and storage

Digital simulation provided clarity and confidence for optimizing processes and investments.

Measurable Benefits Achieved

With insights derived from simulation, Hinduja Tech proposed strategic improvements that enhanced operational performance.

• Highlighted roll test bottlenecks and recommended an additional test station to increase capacity
• Improved offline space utilization by 20%, better managing truck parking and staging
• Confirmed offsite parking could handle inventory accumulation up to 5 days, reducing disruption risks

This approach also enhanced collaboration across logistics, production, and facility teams, driving aligned improvements.

Driving Sustainable, Profitable Innovation

Manufacturers today must embrace smarter, sustainable production. Hinduja Tech’s material flow simulation enables:

• Precise logistics automation and optimization
• Waste elimination and identifying the Bottlenecks
• Resource utilization charts and optimizing buffer sizes
• Enhanced throughput and operational flexibility
• Inventory cost containment without production impacts
• Confident, data-backed planning

By linking simulation with real-world actions, Hinduja Tech fosters resilient, profitable manufacturing transformations.

Why Hinduja Tech is Your Trusted Simulation Partner?

Across automotive manufacturing ecosystems, Hinduja Tech’s material flow simulation capabilities unlock operational transparency, risk mitigation, and strategic capacity planning. By partnering with Hinduja Tech, enterprises gain a trusted advisor poised to deliver:

• Proven methodologies for bottleneck resolution and capacity optimization
• Tailored solution frameworks aligned with complex plant architectures
• Scalable engineering expertise to support evolving production demands
• Robust validation protocols minimizing project risk and maximizing throughput

Embark on your journey towards operational excellence and supply chain agility with Hinduja Tech’s integrated simulation solutions. Discover how our expertise can elevate your manufacturing operations to new levels of efficiency and profitability.

Contact: info@hindujatech.com