What improvement looks like

Illustrative scenarios based on common manufacturing challenges we solve. Real patterns, representative numbers.

These case studies represent composite scenarios drawn from common manufacturing challenges. They illustrate our approach and typical outcomes. Specific client details are anonymised.

ERP Selection

The ERP that almost cost ₹40 lakhs too much

A 200-employee auto components manufacturer was about to sign with a Tier-1 ERP vendor — a system built for companies ten times their size. We conducted a Discovery engagement, mapped their actual process complexity, and identified a right-sized ERP platform that delivered 90% of the functionality at 30% of the cost.

₹28L

Saved on implementation

4 months

Faster go-live

92%

User adoption in first quarter

Approach: Discovery → Vendor evaluation → Implementation advisory

Productivity Improvement

Finding 18% hidden capacity without new equipment

A 150-employee metal fabrication unit felt they needed a new production line to meet growing demand. Before investing ₹1.2 crore in equipment, they engaged us for a productivity assessment. Using video-based shop floor analysis and IE methods, we identified cycle time variations, material handling waste, and line balancing issues that were hiding 18% of their existing capacity.

18%

Capacity unlocked

₹1.2Cr

CapEx avoided

6 weeks

To full implementation

Approach: Video analysis → IE assessment → Process redesign → Implementation support

AI Adoption

From Excel forecasting to demand-aware production scheduling

A 300-employee food processing company was running production scheduling on spreadsheets maintained by two experienced planners. When one planner retired, the system nearly collapsed. We helped them implement a practical AI-based demand forecasting and scheduling tool — not a massive ERP module, but a focused solution that their team could actually use.

35%

Reduction in overproduction waste

₹8L/month

Material cost saving

2 days → 4 hours

Scheduling cycle time

Approach: Process documentation → Tool evaluation → Pilot → Scale

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