- a. Process &
- Material Flow Data Collection:

Review and understand existing plant layout, material flow processes from 3PL Warehouse, to Ather Dock in to Dock out including receiving, Putaway, Decanting, Kitting, Line Side Issuance, Replenishment/ Milk Runs, cycle times for these processes, buffer capacities, and material routing across Assembly and Sub Assembly lines.
- b. 3D / Discrete-Event Simulation Modeling: Prepare, build, and configure energetic material flow simulation models using simulation software tools such as FlexSim, Simulink, (Siemens Plant Simulation).
- c.

Simulation

Execution &
- Scenario Analysis: Run discrete-event simulations to analyze line balancing, identify bottlenecks, evaluate AGV/forklift/operator utilization, assess material handling efficiency, and optimize buffer sizes for Processes.
- d.

Gemba

Exposure &
- Model Parameter Validation: Conduct regular/ frequent visits to the shop floor (Gemba) to physically verify layout, material flow paths, footprints, operator movement, and cycle times against simulation model parameters.
- e. Cross-Functional Optimization &
- Reporting: Collaborate with Ather’s Industrial Engineering (IE) and shop-floor operations teams to validate observed process variations,



review simulation scenario results, and present data-backed recommendations for material flow optimization.
- a.

Verified Simulation

Models: Fully functional, baseline-validated simulation models (built in FlexSim, Simulink representing Ather Energy's material flow and manufacturing zones.
- b.

Material

Flow &

- Bottleneck Analysis Reports: Detailed quantitative reports highlighting throughput constraints, line balancing efficiency, equipment/operator utilization, and buffer optimization across 3PL to Ather Plant (End to End)
- c. Scenario &
- Sensitivity Comparison Studies: Comparative evaluation of "What-If" operational scenarios (e.g., volume ramp-up, layout modifications, routing changes) with actionable throughput improvement recommendations.
- d.

Gemba Parameter Validation

Log: Documented audit log comparing simulation parameters, cycle times, and material handling logic against actual shop-floor operational data.
- e.

Final Simulation

Presentation &

- Model Documentation: Executive presentation of simulation findings and standard operating documentation for future model maintenance and expansion.

📌 Simulation Engineer (Hosur)
🏢 DesignTech Systems
📍 Hosur