GENESIS OF PROBLEM
The plant layout redesign for increase in efficiency was considered necessary because of the following
reasons:
1. Improper material flow through the shop floor i.e., the current plant layout was not designed according to the
process flow given by DGCA.
2. Extended transportation time for material transfer. The sheet metal section had issues to be handled. Based on
the discussion with the manager and supervisors and direct observation by the team, the following problem surface was about non value added operations in the process.