Optimizing Production Line Capacity and Bottleneck Removal in Indian FMCG Manufacturing

Objective: To analyze and optimize the capacity planning and bottleneck removal of a production line to improve throughput and reduce operational delays.

Manufacturing units in India's FMCG sector frequently face constraints in production due to capacity misalignment and bottlenecks, leading to missed demand and operational inefficiencies. Identifying and resolving these issues is crucial for maintaining competitive advantage and meeting market requirements.

The project will focus on a real-world FMCG plant (such as packaged foods or personal care products), where the student team will map out the production process, gather operational data, and identify capacity and flow constraints using quantitative techniques.

Deliverables include process mapping, bottleneck identification using tools like VSM and throughput analysis, simulation of capacity scenarios, and actionable recommendations for process redesign or investment. The analysis will be supported by Excel-based models, flow diagrams, and data visualizations.

The project aims to deliver measurable improvements in line efficiency and guide management decisions on targeted investment or process changes, impacting costs, service levels, and competitiveness.