PUMP RESOURCE PLANNING

capacity utilization analysis

SERVICE AREA:

IMEG partnered with a top-tier manufacturer of industrial pumps to perform a detailed capacity utilization analysis on a complex, 7,000 sq. ft. assembly line consisting of multiple production stages. The objective was to streamline resource usage, reduce bottlenecks, and optimize throughput across the entire line.

THE PROBLEM

No consolidated source for Parts Per Hour (PPH) data or demand volumes
Underutilization of work centers throughout the assembly line
Process bottlenecks had never been fully identified
Undefined routing from assembly to quality testing stages
Lack of a WIP compatibility matrix for the quality control phase
These inefficiencies led to misaligned scheduling, underused resources, and inconsistent throughput

THE PLAN

IMEG deployed a structured resource planning approach that included:

Gathered key metrics including PPH, annual demand, expected uptime, number of shifts, and working hours per shift
Performed detailed capacity analysis across assembly, quality, configuration, painting, and packaging stages
Proposed staffing levels, equipment needs, and layout adjustments to improve flow
Created a WIP compatibility matrix to improve routing and quality test scheduling

production scheduling optimization

THE RESULTS

Calculated precise utilization rates for each stage in the assembly line
Translated findings into equipment and workforce planning recommendations
Delivered a comprehensive scheduling framework, including primary and secondary work center routing based on compatibility data
Successfully identified and mapped all bottleneck areas, enabling focused process improvements
The client now operates with significantly improved visibility into resource needs and has enhanced their ability to scale operations efficiently