
Zero line stoppages in 14 months
Problem
Part-loads from Chakan to plants in Manesar and Hosur arrived 1–2 days late. Two assembly lines stopped twice a month waiting for brackets and harnesses.
Solution
Moved both lanes to dedicated 32 ft FTL on fixed daily slots. Added a cross-dock at Bhiwandi to merge supplier loads, with milk-run pickups from 9 vendors.

