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Overview

Optimizing Efficiency: Revolutionized HMSI’s Approach To WBS Systems

As Honda Motorcycle & Scooter India's Activa scooter sales surged, necessitating a variety of models to stay competitive, they planned to increase production and introduce new models. While their existing conveyor systems could mostly handle this ramp-up with minor modifications, the primary challenge was efficiently organizing the storage of various scooter frames to keep up with production.



Customer Profile

Industry: Automotive

Locations: Haryana, India

Problem Statement

The main bottleneck was the organized storage of different scooter frames models to match production takt in various shops, requiring a system that could handle storage and facilitate FIFO (First In, First Out) logistics.

Key Metrics

  • Store 1000 frames efficiently
  • Maintain production flow without disturbances
  • Ensure minimum investment
  • Install the conveyor in a running line without disturbing production
Background

AUTOMAG's Solution

Automag implemented a state-of-the-art light duty power and free conveyor system to solve Honda’s warehouse challenge.

01.

System allowed for organized storage and automated, model-wise retrieval of scooter frames, ensuring efficient handling of over 1000 frames.

02.

Custom designed the carrier to store 2 frames and 2 body covers in one carrier. Hence, we reduced the number of carriers required and the conveyor length.

03.

Completed installation and commissioning during night shift without disturbing existing production.

04.

The integration with PLC system enabled automated control, enhancing the system’s reliability and efficiency.

Results

Increased Production Efficiency: Balanced the throughput between weld and paint shops, serving as an emergency buffer to maintain production continuity.

Reduced Unnecessary Movement: Reduced trolley movement, optimized space utilization and enabled real-time monitoring of frame storage and retrieval.

Cost Savings: Production costs were reduced, due to improved operational efficiency and drastic reduction in trolley movement.

Conclusion

The storage system not only addressed the throughput differential but also provided resilience during maintenance downtimes and enhanced operational efficiency.


Customer Feedback

Honda was very satisfied with the solution, noting minor debugging issues but expressing overall happiness with the project’s outcome. They subsequently requested an additional system for the paint shop.