Gear Manufacturing Process Flow Optimization – Revathie Gear Products

Mapped the end-to-end process for sprocket manufacturing, from raw-material cutting through gear hobbing and quality inspection. Used VUT analysis to identify teeth-cutting and QC as the primary bottlenecks, then built a detailed Arena simulation model to test layout changes, capacity additions, and in-house process integration. Ran multiple scenarios and recommended a revised routing and capacity plan that lifted weekly sprocket output from 16 to 25 units (53% increase) and cut average waiting time at the bottleneck by 13.6 minutes, improving on-time delivery potential without major capital expenditure.