Representative End User Clients
Representative Automation Clients
Representative Software Clients
Client’s Challenge: A global medical equipment manufacturer sought to double production of hospital beds by improving productivity and addressing in-process quality concerns. The objective was to analyze value-added (VA) and non-value-added (NVA) process activities, eliminate waste, reduce downtime, and identify the root causes of quality rejections. The proposed countermeasures would aim to improve "Right First Time" (RFT) performance, thereby increasing overall productivity to meet market demand. Given L&T Technology Services' (LTTS) extensive manufacturing and industrial engineering expertise, the client requested a pre-motion time study to eliminate waste, balance the 
assembly line, and establish a 35 percent RFT baseline through process improvements.
The Solution: LTTS developed an effective working model by examining their assembly process and starting a Predetermined Motion Time Study (PMTS) to find waste. This was followed by Value Stream Mapping to identify and eliminate waste. Also, LTTS understood the need of optimizing their line layout and standardization of the process flow and work instructions. This created a lean assembly line designed for better efficiency, and here are some key points:
• Lean Assessment & Layout Optimization: Identified the root causes for quality rejections and proposed counter measures to improve RFT. Identified gaps in training methods and suggested improvements to effectiveness of training. Additionally, improved the assembly line layout using Best Value Option Analysis (BVOA) and tested the layout for future needs with material flow simulations.
• Value Stream Mapping & Standardization: Assisted the client in mapping current state VSM, captured video for time study and performed VA, NVA analysis and eliminated waste. Also, rebalanced the assembly line to meet targets and verified the process using the discrete event simulation tool, FlexSim.
Key Achievement: LTTS successfully improved the layout and boosted productivity and RFT by achieving the following results:
• Improved Productivity: 54 extra beds produced with increased output from 46 to 100 and reduced fabrication downtime by 10 percent.
• Optimized Inventory and Workspace: Space usage improved by 38 percent by analyzing the low-volume, high-mix production setup. Also reduced the workforce by 22 percent by recommending 14 Automated Guided Vehicles (AGVs) to enhance process and material flow, which helped manage high inventory levels.
• Standardization: Manufacturing process lead time reduced through Value Stream Mapping (VSM) of all production lines and implementing improvement Kaizens. Also established better quality standards and created consistent process flow documentation and work instructions across different product families.
Thanks to positive feedback from the client, LTTS has established itself as the preferred partner for the medical equipment manufacturer over the long term.