Manufacturing challenges rarely fit a template — and neither do our engagements. Each situation below required a different diagnosis, a different intervention, and a different kind of staying power to see it through.
01
Greenfield Manufacturing Setup · Consumer Durables
Strategic Plant Setup and Business Launch
Led the establishment of a greenfield manufacturing operation from concept to commercial production. Directed site selection, plant layout, manufacturing systems, team development, supplier ecosystem creation, and governance frameworks. The challenge was not just building a plant — it was building a business from scratch, in a new market, with a new team, under intense time pressure. Delivered on schedule and within budget, with the operation reaching profitability in year two.
02
Productivity Improvement · Automotive Tier 2
Turnaround Through All-Round Excellence
Led a WCM-driven transformation following a sharp EBITDA decline from 11% to 7%. The root cause wasn't one thing — it was six concurrent performance losses across quality, productivity, cost, and process stability. We identified each one, sequenced the interventions, and drove implementation with the plant team rather than around them. The result was a strong operational recovery within 14 months, with productivity up, rejection rates down, and EBITDA back on track.
03
Supply Chain Transformation · Consumer Durables
Inventory Build-Up and Service Challenges
Led a comprehensive diagnostic that identified planning process weaknesses and supplier lead-time variability as the two key root causes of a growing inventory problem. The business was tying up working capital in the wrong places while simultaneously missing customer commitments. We implemented structural improvements in demand planning, inventory management, and supplier coordination — reducing inventory levels while significantly improving customer fulfilment rates at the same time.
04
Product Industrialisation · Automotive OEM
Complex New Product Launch
Led the successful introduction of two distinct India-focused vehicle models from a shared manufacturing platform. This required rigorous supplier development, disciplined APQP execution across a complex supply base, cross-functional collaboration between engineering, procurement, and manufacturing, and robust cost engineering to hit local content targets. Both models launched on time, on cost, and with the manufacturing readiness and quality levels needed to sustain a high-volume ramp-up from day one.
🔒
Client names are kept confidential as part of our standard engagement terms. Every situation, intervention, and result shown here reflects an actual engagement — not a composite, not a projection, not an industry benchmark. If you want to understand the methodology behind any of these, we are happy to talk through it.