Improving Paint Shop Productivity

The following account focuses on how Tractors and Farm Equipment’s Paint Shop Productivity Project tackled various challenges to enhance efficiency, meet increasing production demands, and prepare for future growth.

It Tractors and Farm Equipment Ltd (TAFE), Bengaluru, the paint shop team faced a challenge and opportunity to significantly reduce losses and improve plant efficiency by increasing productivity to meet growing delivery targets. With the increasing demand for new models of tractors (NPI tractors) in the market, we needed to streamline processes and ensure the right model of tractor reached the right dealer at the right time. The solution was clear—optimize the paint shop's capacity to support new product adoption without compromising regular production.

To maintain its customer-centric approach and market leadership, the team embarked on an ambitious productivity enhancement project aimed at improving the delivery process and plant performance. This initiative aimed not only to meet the immediate demand but also to position the company for future growth by improving efficiency, sustainability, and innovation.

Hence, this productivity enhancement project supported in focusing the bottleneck areas within the paint shop process and implemented targeted improvements to reinforce our dedication to exceed customer expectations to uphold organization core value and to play a market leader in the industry.

Meeting New Products Demand

TAFE’s commitment to providing quality and timely tractor deliveries is rooted in its dedication to customer satisfaction. The need for new models of tractors required to thoroughly assess its manufacturing plant capacity. The key challenge was ensuring that production could accommodate these new models while maintaining regular operations at scale.

The primary objective of this productivity enhancement project was to increase the painting capacity in order to meet the increased demand from the tractor business. This ambitious goal required a detailed understanding of the paint shop’s processes, identify the areas for improvement, and execute strategies to optimize the workflow.

Overcoming Key Challenges

While striving to achieve productivity improvement goals and objectives, we encountered several challenges:

• Increase in Operating Costs: Rising costs made it essential to optimize operations without compromising quality.
• Capital Expenditure (CAPEX) Requirements: Investment in new technologies and equipment was necessary to ensure long-term gains.
• Environmental Effects: The team had to address environmental concerns while improving productivity.
• Traditional Training Facilities: There was a need and drive to change from the existing training methodologies to accommodate new technologies and processes.
• People Mindset on Training: Shifting the mindset of employees to embrace new training programs was a significant hurdle.
• Lack of Certified Trainers: The need for specialized trainers to impart advanced skills and knowledge in emerging technologies was paramount.

The team recognized that the key to overcoming these challenges lay in adopting a holistic approach that balanced productivity enhancements with environmental responsibility.

Methodologies for Success

To achieve the desired productivity gains while ensuring sustainability, the team employed several advanced methodologies:

Process Re-Engineering:

A core aspect of the project was the redesigning of the existing processes. This involved:

• New Loading Pattern: Shifting from the old to a new loading pattern, which was more efficient and better aligned with paint shop productivity goals.
• Gap Identification: Identifying bottlenecks and areas that required immediate attention to prevent delays in production.
• Modification of Secondary Hangers, Jigs, and Hooks: Upgrading equipment to accommodate improved workflows.
• Layout Optimization: Modifying the line layout to improve space utilization and material flow.

Leveraging Digital Enablement:

In the era of Industry 4.0, digital solutions play a critical role in driving efficiency. Hence, the team incorporated several cutting-edge technologies, including:

• Digital Monitoring Systems: Real-time monitoring systems such as Supervisory Control and Data Acquisition (SCADA) systems were introduced to track every stage of the painting process.
• Virtual Reality (VR) Based Training: This technology allowed for hands-on training experiences without the need for physical equipment, reducing training time and costs.
• Simulation Modules: Through real-time simulations, trainees could experience real scenarios and improve their decision-making skills without any production downtime.

Optimizing Flow Manufacturing:

To further improve efficiency, we optimized the manufacturing flow:

• VMAP 1 and 3S MAP: Streamlined value stream mapping processes helped identify waste and redundancies within the production line.
• Heijunka: Implemented to ensure balanced production and reduce fluctuations in paint shop workflow.
• Space Utilization: Optimized material storage areas to free up space for more efficient material handling.
• Safety Considerations: Minimized hazards and improved workplace safety by mapping potential safety risks.
• RMS & IMS Mapping: Ensured smoother communication and less downtime by systematic mapping of resource management and information systems.

Skill Development:

A well-trained workforce is key to maintaining productivity, and we took proactive steps in upskilling our employees:

• Virtual Simulations and Real-Time Simulations: Employees were trained using VR to practise their roles in a controlled, risk-free environment.
• Role Effectiveness of Sprayers: Special training was provided for sprayers, focusing on technique and efficiency.
• Train-the-Trainers Program: To ensure continuous skill enhancement, a master trainer program was launched to develop in-house certified trainers capable of passing on the knowledge to new recruits.

Results and Achievements

After implementing these productivity improvements, the capacity for painting tractor sets per hour saw a significant increase across all painting lines. This success not only met the initial business requirements but exceeded them, providing the company with the ability to accommodate the growing demand for tractors.

By surpassing targets, we demonstrated an unwavering commitment to innovation, operational excellence, and customer satisfaction. The enhanced processes have laid the foundation for future growth, positioning us as a market leader in the Tractor Manufacturing industry.

Painting capacity (average) increased from 13 to 25 per hour though jig density optimization at the success rate of 92.3 percent. 

Environmental benefits were also achieved as 2,852 tonne of CO₂ emission was reduced and 400 litres per tractor of water saved.

Conclusion

The Paint Shop Productivity Project at TAFE has been pivotal in driving efficiency, sustainability, and excellence in every aspect of production. By addressing challenges and adopting transformative strategies, we have not only met our objectives but have also set a benchmark for future productivity initiatives. As the demand for new tractor models continues to grow, TAFE’s dedication to continuous improvement and innovation ensures it will remain at the forefront of the industry, meeting customer expectations and achieving long-term success.

Murugadas P Project Leader Divisional Manager – Paint Shop Tractors and Farm Equipment Ltd

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