CASE STUDY - Total Turnkey Project-Auto-parts Assembly Line



Client is a leading global supplier of drivetrain, mobility, braking, aftermarket and electric powertrain solutions for commercial vehicle and industrial markets. With more than a 110-year legacy of providing innovative products that offer superior performance, efficiency and reliability, the company serves commercial truck, trailer, off-highway, defence, specialty and aftermarket customers around the world.



• To plan, execute, and deliver a comprehensive turnkey solution for the design, manufacturing, testing, installation, and commissioning of an advanced auto part assembly line, ensuring seamless integration of components, efficient production processes, and compliance with industry standards. The project aims to optimize productivity, quality, and safety while meeting client specifications within the designated timeline and budget

• Designing a new product line centered around the concept of turnkey solutions while optimizing resources presented a multifaceted challenge. This endeavour demands a holistic approach that carefully balances various elements of Design Engineering, Industrial Engineering & Production Engineering to achieve seamless, efficient, and cost-effective solutions.


What We Did:
Concept development and Process design

First and foremost, we dwelved into extensive research and analysis to gain a deep understanding of the suspension assembly domain with process experts. Our next step was to develop a robust concept, which was grounded in the insights gained during our research phase. We assembled a cross-functional team comprising engineers, designers, and subject matter experts to brainstorm, ideate, and iterate on various concepts. Once the concept was established, we proceeded with the process design phase. This involved a meticulous mapping of the assembly process, considering factors like materials selection, manufacturing techniques, quality control procedures, and resource optimization. We harnessed cutting-edge technology, software tools, SMED and turnkey solutions to create a detailed process flow that ensured efficiency, cost-effectiveness, and a high standard of quality throughout the assembly process.


Ergonomically designed workstation to reduce fatigue

we followed a systematic and user-centric approach, studying the physiological and psychological factors that influence workplace comfort and performance. We conducted surveys and interviews with potential users to understand their specific needs, pain points, and preferences. We built physical and digital prototypes of the workstation, allowing users to interact with the design and provide feedback. The end result was a workstation that not only promoted comfort but also enhanced productivity.


Poka-Yoke for all critical requirements

we initiated an in-depth analysis of our critical requirements, identifying potential areas of error or deviation. We recognized that these critical aspects of processes were particularly vulnerable to mistakes or oversights, which could lead to defects or operational inefficiencies. We reviewed workflows, assembly lines, and quality control measures to pinpoint opportunities for error reduction or elimination. Through this analysis, we identified common human errors, missteps, and potential failure points. Subsequently, we devised and integrated Poka-Yoke mechanisms into these processes.

Throughout this process, we also prioritized training and education. Ensuring that all team members were well-informed about the implemented Poka-Yoke techniques was vital for their effectiveness. We conducted regular training sessions and engaged in ongoing monitoring to fine-tune and improve the error-proofing measures. The ultimate goal was to design fail-safes that prevented errors from occurring.


Key results

• Delivered the project at 60% of nearest competitor pricing
• Handed over the project 4 weeks ahead of quoted lead time
• Lean Line Design of Shop floor to incorporate best productivity by minimizing the wastes
• SOP’s and Poka Yoke implemented for all critical processes.