Building a smarter production line for a global automobile manufacturer

The client faced significant operational challenges with its existing production planning tools, particularly when visualizing the UB line layout. The static models in place lacked the flexibility to simulate production flow or parts movement, limiting the team’s ability to plan effectively.

Without a real-time simulation environment, validating design choices and identifying potential bottlenecks became an ongoing challenge. To move forward, the manufacturer needed more advanced visualization capabilities—an essential first step toward building a future digital twin of the entire operation.

The AI-powered visual twin helped to deliver tangible value across the design and planning life cycle, including:

• Improved design validation through immersive visualization of plant layout, equipment positioning, and material flow in a shared 3D environment
• Earlier identification of inefficiencies and space constraints before physical construction began
• Reduced time and cost in layout finalization, enabled by rapid iterations and visual simulation.
• Enhanced scenario planning, allowing teams to explore multiple “what-if” scenarios to support productivity, safety, and sustainability goal
• Stronger stakeholder alignment through a shared, visual digital twin

By elevating visibility into core manufacturing operations, Deloitte India helped the client not only address an immediate challenge but also establish a trusted foundation for future innovation.