Executive Summary
Apex Automotive, a mid-sized tier-2 supplier of automotive sub-assemblies, was struggling with high labor costs, inconsistent production output, and rising worker compensation claims due to repetitive strain injuries. By implementing Taktimize to optimize their primary motor assembly line, Apex was able to consolidate their workstations, significantly increase Line Balancing Efficiency (LBE), and drastically reduce ergonomic risks—saving an estimated $120,000 annually.
The Challenge
Before Taktimize, Apex Automotive's production engineers relied on manual spreadsheets to balance their assembly lines. As product complexity grew, this manual process became unsustainable. They faced three critical issues:
- Severe Line Imbalance: The line had a Line Balancing Efficiency (LBE) of only 65%. Some workers were completely overwhelmed, creating bottlenecks, while others spent up to 35% of their shift idle.
- High Ergonomic Risk: Without an easy way to factor ergonomics into line balancing, several workstations required awkward postures (heavy lifting and excessive trunk twisting). The average REBA score across the line was a dangerous 7.2 (High Risk).
- Inflexibility: When demand fluctuated or a worker called in sick, it took engineers hours to recalculate and redistribute tasks, leading to costly downtime.
The Solution: Taktimize
Apex Automotive imported their existing time-study data (45 distinct tasks) directly into the Taktimize platform using the Excel template. Within seconds, the Taktimize engine processed thousands of potential combinations, respecting strict precedence constraints and exclusive resource requirements. The software generated multiple optimized scenarios for the engineering team to review.
Key Features Utilized:
- Simultaneous Optimization: Taktimize balanced the line not just for time, but also for ergonomic safety, ensuring no single worker was overloaded with high-risk REBA tasks.
- Conflict & Combine Groups: Engineers easily set rules to ensure tasks requiring the same heavy crane were grouped together, while incompatible tasks (like welding and sensitive electronics testing) were kept separated.
- Visual Dashboard: The built-in Stacked Workload Chart allowed management to instantly see where idle time was eliminated.
The Results
By adopting the optimal scenario recommended by Taktimize, Apex Automotive achieved transformative results in less than a week:
| Metric | Before Taktimize | After Taktimize | Improvement |
|---|---|---|---|
| Total Workstations | 12 | 10 | Reduced by 2 (16%) |
| Line Balancing Efficiency | 65.2% | 88.5% | + 23.3% |
| Average REBA Score | 7.2 (High Risk) | 3.8 (Low Risk) | 47% Safer |
| Max Bottleneck Time | 45.0s | 36.2s | Output increased by 19% |
Financial Impact
- Labor Savings: By reducing the required headcount on this specific line by 2 operators per shift (across 2 shifts), Apex saved approximately $95,000/year in direct labor costs.
- Safety & Retention: By lowering the REBA scores and distributing physical strain evenly, Apex projected a $25,000/year reduction in injury-related costs and absenteeism.
Final ROI
Achieved in less than a week of implementation
"What used to take us three days of arguing over spreadsheets now takes 30 seconds. Taktimize didn't just save us money on headcount; it made our workers' jobs significantly safer."
— Lead Production Engineer, Apex Automotive
Conclusion
For factory owners and production managers, Taktimize bridges the gap between theoretical industrial engineering and practical, day-to-day shop floor management. As demonstrated by Apex Automotive, investing in algorithmic line balancing yields immediate, measurable ROI in both profitability and worker wellbeing.