Smarter Factories, Optimized Assembly lines and Leaner scheduling systems is future of Production and Factors across the world.
Vijay Gurav
In an era defined by rapid shifts in demand and increasing product variation, high-mix, low-volume (HMLV) manufacturing has emerged as one of the industry’s greatest challenges. To understand how manufacturers are adapting, we sat down with Vijay Gurav, Senior Industrial Engineer at Boston Whaler, USA, and author of Modern Industrial Engineering and Factory Assembly Line Systems. Gurav is at the forefront of a new wave of production thinkers redefining how we approach scheduling in complex manufacturing environments such as Fiberglass Boat Manufacturing.
In an era defined by rapid shifts in demand and increasing product variation, high-mix, low-volume (HMLV) manufacturing has emerged as one of the industry’s greatest challenges. To understand how manufacturers are adapting, we sat down with Vijay Gurav, Senior Industrial Engineer at Boston Whaler, USA, and author of Modern Industrial Engineering and Factory Assembly Line Systems. Gurav is at the forefront of a new wave of production thinkers redefining how we approach scheduling in complex manufacturing environments such as Fiberglass Boat Manufacturing.
Q: Vijay, what makes HMLV production so difficult in today’s market?
Gurav: In today’s competitive and rapidly shifting markets, manufacturers are increasingly faced with the challenge of producing a wide variety of products in smaller quantities. Known as high-mix, low-volume (HMLV) production, this environment demands precision, flexibility, and a radical rethinking of traditional production scheduling techniques.
Unlike mass production, HMLV involves frequent changeovers, varied customer demands, and intricate scheduling needs. Factories must respond quickly to new orders while minimizing downtime and avoiding waste. That’s why engineers and Lean experts are now working on tailored strategies that maintain both efficiency and adaptability.
Q: You’ve developed your own agile scheduling model. What does it focus on?
Gurav: My recent research is centred around agile production scheduling systems in Boat Manufacturing which is categorical can be applied in any HMLV Factories. These systems dynamically adjust crew sizes, workstation allocations, and part sequencing based on real-time data and part requirements. Especially in HMLV setups-where some parts might only be needed once every few weeks-the focus is on uninterrupted batch completion and strategic crew deployment.
“HMLV production isn’t chaotic by nature-it just requires a different logic. You have to treat scheduling as a living system-one that adapts to each product’s flow, takt time, and setup constraints. That’s how you avoid bottlenecks and keep throughput consistent.”
Q: How do your ideas align with Lean manufacturing traditions?
Gurav: My approach builds on foundational Lean principles. For instance, Taiichi Ohno from the Toyota Production System emphasized heijunka, or leveling production, even in mixed-model Assembly lines. Similarly, Art Byrne, the former CEO of The Wiremold Company, always advocated for visual controls and scheduling simplicity to manage complexity. I see my work as a digital evolution of those timeless ideas.
Q: Are manufacturers already putting these scheduling strategies into action?
Gurav: Yes-companies like GE Appliances and Bosch are great examples. They’re already integrating digital kanban systems, modular workstations, and real-time dashboards into their HMLV operations. These tools help prioritize jobs not just by due dates, but also by considering resource availability, material readiness, and workforce flexibility.
Q: Finally, where do you see the future of HMLV production heading?
Gurav: The goal is no longer just to schedule faster-it’s to schedule smarter. We’re moving toward intelligent, adaptive systems that balance Lean principles with real-time data and predictive tools. It’s an exciting space where traditional manufacturing wisdom meets digital innovation, and the potential is enormous. Smarter Factories, Optimized Assembly lines & Leaner scheduling systems is future of Production & Factors across the world.
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