case studies

Case studies:

1. Turnover Growth with Profitability Boost:
   A ₹7 crore turnover company expanded to ₹35 crore within 2 years. Profit contribution improved significantly from 12% to 24% through strategic business interventions.
   
   

2. Operator Productivity Multiplied:
   Shifted from one operator per machine to one operator managing three machines. This tripled manpower efficiency without additional hiring.
   
   

3. Digital Transformation via ERP:
   Manual processes managed through Excel for 150 employees were fully converted to an ERP system. This resulted in streamlined operations and improved accuracy.
   
   

4. Production Ramp-Up with Minimal Resources:
   Production scaled from 3,00,000 to 5,00,000 units without adding any new resources. Later, by adding just 2 machines, the company achieved a record 6,00,000 units output.
   
   

5. Generational Alignment through Role Clarity:
   Facilitated role balancing and goal setting between the company’s first and second-generation leadership. Enabled smooth succession and strategic alignment.
   
   

6. Lean Plant Layouts Implemented:
   Designed and implemented over 15 plant layouts based on Lean manufacturing concepts. These layouts optimized space, material flow, and efficiency.
   
   

7. Productivity Enhanced Across Business Types:
   Achieved 40%+ productivity gains across six industry types: Mass, Batch, Project, Discrete, Process, and Services through customized Lean management interventions.
   
   

8. TPM Boosted Machine Availability:
   Implemented Total Productive Maintenance (TPM) for over 150 machines. Resulted in more than 25% improvement in machine availability.
   
   

9. Micro Unit Transformation:
   Revamped a struggling micro enterprise into a ₹2 crore turnover success story through operational and strategic upgrades.
   
   

10. SCM & SRM Integration for Agri-Equipment Firm:
    Developed a robust Supply Chain Management (SCM) and Supplier Relationship Management (SRM) system for an agriculture equipment manufacturer, ensuring reliability and scalability.
    
    

11. Business Autopilot via SLA & ERP:
    With the help of Service Level Agreements (SLA) and Google-based ERP, one of the three business units of an entrepreneur was made self-sustaining and autopilot-ready.
    
    

12. Second Line Leadership Developed:
    Built a strong second line of leadership, maintaining the same turnover and profitability. The entrepreneur now visits the factory just once a month.
    
    

13. Revenue Boost through QCDD Excellence:
    Secured 50% additional revenue from the same customer by consistently delivering excellence in Quality, Cost, Delivery, and Development (Q.C.D.D.).
    
    

14. New OEM Customers through System Excellence:
    Acquired 3 new OEM clients by successfully implementing Integrated Management Systems (IMS), ERP, Visual Factory practices, and audit-ready departments.
    
    

15. PO to Invoice Lead Time Cut by 81%:
    Reduced purchase order to invoice cycle time from 16 days to just 3 days. This enabled a 3x increase in sales within six months.
    
    

16. Lead Time Cut and Inventory Savings:
    Reduced a 3-month lead time to just 15 days. Achieved one-time inventory and working capital savings worth ₹40 lakh.
    
    

17. Freight Cost Optimization via Lean Logistics:
    Reduced freight cost by 45% using Kanban and milk run logistics. One-time savings of ₹20 lakh were achieved.
    
    

18. Inventory Accuracy and Cleanup:
    Eliminated stock variances in a mass production unit by implementing BPS, PIC, KANBAN, ERP, and HEIJUNKA. Settled ₹1.5 crore of mismatched inventory.
    
    

19. Leadership Transition without Downtime:
    On sudden exit of the plant head, the role was dissolved. Responsibilities were smartly distributed among Purchase, Production, and PPC without impacting plant performance.

Client Gains