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