About the Client

A plant assembly integrator focused on the growing electric mobility segment. The client partnered with CS TECH Ai to plan and design a lean manufacturing facility for producing eight electric two-wheeler variants, optimized for speed, quality, and cost-efficiency.

The Challenge

The client needed to establish a digital lean manufacturing facility capable of delivering high-quality output across multiple EV variants — while keeping capital investment low and operational efficiency high. The complexity lay in balancing ergonomics, process modularity, and flexibility across product lines.

Key challenges included:

• Designing a scalable plant for eight electric scooter variants
• Minimizing capital investment while meeting productivity goals
• Aligning plant layout and assembly flow with lean manufacturing principles
• Integrating logistics, ergonomics, and digital factory planning

The Solution

We executed a 3-stage approach to deliver a fully optimized plant plan aligned with lean and digital manufacturing standards.

Key solution components included:

• Stage 1 – Assessment and Recommendations
  • Collected and analyzed baseline plant data
  • Developed a recommendation report with actionable insights
  • Defined key performance indicators (KPIs) for cost, quality, and productivity
• Stage 2 – Concept Engineering
  • Designed innovative assembly layouts and in-plant logistics flows
  • Integrated lean manufacturing principles into material movement, workstations, and ergonomics
  • Developed modular concepts to accommodate variant flexibility
• Stage 3 – Detail Planning
  • Created comprehensive digital factory layouts and simulation-ready models
  • Generated detailed manufacturing drawings
  • Aligned plant infrastructure with future automation and Industry 4.0 readiness

The Impact

The project established a world-class foundation for electric two-wheeler production:

• Streamlined plant layout optimized for lean flow and minimal waste
• Improved productivity and quality through ergonomic design and material flow optimization
• Reduced capital investment via modular and standardized assembly lines
• Future-ready facility built on digital twin principles for scale and flexibility
• Accelerated launch readiness for a fast-growing EV product portfolio