Clients | Success Stories
Almost all our clients have reported significant operations results within few months of our engagement. We have helped some of them use the superior operations capability to build a decisive edge in the market to impact sales and bottom line.
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Listen to Niranjan Kirloskar CEO of Fleetguard Filters. Presenting how his company got dramatic improvements using the theory of constraints. |
Fleetguard Filters
The company has increased profits by 6 times in the last 4 years, and sales by 3 times. The company operates at near 100% availability for its customers while maintaining over 17 inventory turns....
Liberty Shoes
The company has achieved over 95% availability in its central warehouse. The production lead time has dropped from 45 days to 25 days with 30% reduction in WIP and FG inventory.
Top1 Lubricants
TOP1 reduced its inventory from 7 months to 2 months in its warehouses in Indonesia, while improving availability to near 100%.A Leading Switchgear Manufacturer
Record Production Levels month on month from the third month, achieved more than 50% rise in plant output
Godrej Interio
Using the Theory of Constraints solutions, the Office Furniture Division (OPUS) of Godrej Interio achieves on time delivery of 98%+, on the original committed customer dates. The lead time has reduced by 30% to 50% in various categories. There has been about 20% capacity release in the manufacturing facility besides about 80% reduction in expediting costs like air shipments and overtime.Tool and Die Cast Die Manufacturer
Die Cast Dies and Panel Tools manufacturing major increases on time delivery from below 8% to more than 90%, while reducing lead time by 25%
TRF
The bulk material handling systems division delivered 30% more output as compared to last year, from existing resources. The design lead time has come down to 3 months from an average of 8 months...
Tata Metaliks
Tata Metaliks sets an industry benchmark in executing Blast Furnace relining shut down. The shutdown was completed in record 23 days with 25% extra scope and with expenses at 87% of the initial budget. Peak plant production reached in record 10 days.
Abhishek Industries
Using CCPM, Abhishek Industries (Trident Group) erects spinning plant of 30,000 spindles, a green field project, in record time of 9 months as compared to industry benchmark of 12 months. The ramp up to peak production was also achieved in 40 days as compared to typical industry time of 3-4 months.
Fleetguard Filters
Major player in manufacturing and distribution of automotive filters.The company has increased profits by 6 times in the last 4 years, and sales by 3 times despite the recession in auto market in the year 2008-09. The company operates at near 100% availability for its customers (OEM and retail) while maintaining over 17 inventory turns. It has been increasing sales in after market (retail) by over 60% year on year for the last 3 years with inventory turns of over 23 (while most in auto parts distribution are at about 2-3 inventory turns). The rate of new products developed has tripled using the same capacity.
Liberty Shoes
One of the leading companies in fashion footwear industry.The company has achieved over 95% availability in its central warehouse, which is probably amongst the best in the fashion industry. The production lead time has dropped from 45 days to 25 days with 30% reduction in WIP and FG inventory. This released cash for working capital has also improved the availability of Finished Goods. The company has rolled out the offer of high inventory turns and high availability to the wholesalers and the retail shops. Most clients have reported more than 30% jump in sales with improvement of inventory turns from 2 to more than 5.
Top1, Indonesia
One of the largest distributors of engine lubricants for automobiles in Indonesia.TOP1 sources the oil from USA. With Vector, TOP1 reduced its inventory from 7 months to 2 months in its warehouses in Indonesia, while improving availability to near 100%. In the first phase of the roll out of the retail replenishment solution to select retailers, the range of the company's products available at the retailer has more than doubled and the distributor's reach has increased by over 50%.
JK Files and Tools
Leading manufacturer of tools and files.JK files started TOC implementation on August 2009. Within 2 months the lead time was reduced by 40%. Plant output has gone up by35%, across 5 locations. One of the plants has shown an increase of over 70%. The company will now be rolling out retail offers in its distribution channel tofurther boost the sales.
Filtrum Polymers
The company supplies rubber parts to auto first tier suppliers.When the TOC implementation started in Oct 2009, the company was at 6% PBT. Now the company is at 15%PBT with 60% increase in sales. It has 100% delivery performance to all its auto parts customers. It has released more than 60% additional capacity in the last 6 months. Inventory turns have improved by 50%.
Filtrum Tools
Manufacturer of tooling for auto sector.With the implementation of CCPM, Filtrum has been able to reduce the overall lead time by 25%, while improving the on-time delivery performance to about 90%.
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Tata Bluescope Steel
Godrej Security Solutions| • | On Time Performance of the Plant is now more than 90% , while the production lead time is reduced by 43% |
| • | Output in the plant has increased by more than 50%. (This has been achieved with elimination of overtime expenses and 14% reduction in manpower, on account of attrition) |
| • | WIP is reduced by more than 40% and the FG inventory is reduced by 50% |
| • | Sales has increased by 38%, while the profitability of the division has more than doubled. |
Fleetguard Filters
Leader in manufacturing and distribution of automotive filters to commercial vehicle segment.
Fleetguard Filters has implemented TOC company wide to achieve significant improvements in financial and operational results. In the 5 years of engagement with Vector, the sales have increased 4 times and profit 8 times. The growth Isinspite of the commercial vehicles industry growing at about 15% CAGR. It provides near 100% availability to its OEMs. The new product development is half the previous lead times. The output of the new product development has increased 5 times in last 3 years.Its After Market distribution now operates at a new industry benchmark of 20 inventory turns with over 98% availability at all stocking points, including distributors. The distributors have this availability at 10-12 days inventory.
Liberty Shoes
One of the leading companies in fashion footwear industry.
The company has achieved over 97% availability in its central warehouse, which is probably amongst the best in the fashion industry. The production lead time has dropped from 45-60 days to 17 days. The total inventory has reduced from 125 days to 65 days. The company after flat sales for about 4 years till 2009-10 has increased sales by 15% in 2010-11 and 25% in 2011-12. The company has rolled out the replenishment offer to its showrooms and distributors, which provides offer of high inventory turns and high availability. Most clients have reported more than 30% jump in sales with improvement of inventory turns from 2 to more than 5.
Liberty Retail Revolutions Ltd
Retail chain with about 80 stores across India, selling fashion footwear.
In the first year it improved the store inventory cover from 10 months to 5 months, while increasing sales by 30%. The released capital was used to add 30 stores to the existing 50. The company will have another 20% growth in 2011-12 without infusion of capital.
Top1, Indonesia
One of the largest distributors of engine lubricants for automobiles in Indonesia.
TOP1 sources the oil from USA. With Vector, TOP1 reduced its inventory from 7 months to 2 months in its warehouses in Indonesia, while improving availability to near 100%. Top1procures most if all its products from US. In the first phase of the roll out of the retail replenishment solution to select retailers, the range of the company's products available at the retailer has more than doubled and the distributor's reach has increased by over 50%.
A Leading Switchgear manufacturer
Record Production Levels month on month from the third month, achieved more than 50% rise in plant output.
JK Files and Tools
Leading manufacturer of tools and files.
Using TOC solutions, JK tools has increased output by 30% from current capacity in 6 months of implementation. Its plant in Kolkota doubled its output in one year.
Filtrum Polymers
The company supplies rubber parts to auto first tier suppliers.
In one year the sales increased by nearly 50%, and PBT increased from 6% to 18%. It has 100% delivery performance to all its auto parts customers. It has released more than 60% additional capacity in the first 6 months of implementation Inventory turns improved by 50%.
Godrej Interio
One of the leading players in office furniture systems, the company designs, manufactures and commissions as per customer preferences.
With implementation of DBR and CCPM solution components, the office furniture division of Interio improved the on-time performance from an average of 50% to over 98% in 2 months of starting the implementation and has been maintaining the performance for the last 18 months. There has been 70% reduction in WIP and 40% reduction in Finished Goods inventory. The lead time has reduced by 30% to 50% in various categories. There has been about 20% capacity release in the manufacturing facility besides about 80% reduction in expediting costs like air shipments and overtime. The division has improved the overall profitability by improving the mix of lucrative small orders, where customers demand lower lead times.
Tool and Die Cast Die manufacturer
Die Cast Dies and Panel Tools manufacturing major implements multi-project CCPM to improve on-time delivery (as per originally committed dates) from 8% to 90%+ in 4 months.
Filtrum Tools
Manufacturer of tooling for auto sector.
With the implementation of CCPM, Filtrum has been able to reduce the overall lead time by 25%, while improving the on-time delivery performance to about 90%.
TRF Ltd: Bulk Material Handling Solutions Div
The Bulk Material Handling Solutions Division, is a leading EPC player for large coal handling solutions.
With the implementation of multi-project CCPM solution, the company delivered 80% more billing in first two years, by the end of the 3rd year (2011-12) it will increase to near 100%. The nemesis of any projects company projects delivered but still not closed due to some issue, which engage key resources but also lock in huge cash as receivables. TRF has no open projects! The design leadtime has come down to 3 months from an average of 8 months, while the design iterations have dropped from an average of 6 to about 1.2.
Tata Metaliks
World’s largest producer of Pig Iron.
Tata Metaliks sets an industry benchmark in executing Blast Furnace relining shut down using CCPM. Blast Furnace relining shut down completed in record 23 days with 25% extra scope and with expenses at 87% of the initial budget. Peak plant production reached in record 10 days. Usually the lead time of such shutdowns and revamps is between 45-60 days, and reaching peak production takes about 3 months.
The earlier similar project was completed in 30 days.
Abhishek Industries
One of the leading players in textile industry.
Using CCPM, Abhishek Industries (Trident Group)erected a spinning plant of 30,000 spindles, a greenfield project, in a record time of 9 months as compared to the industry benchmark of 12 months. The ramp up to peak production was also achieved in 40 days as compared to the typical industry time of 3-4 months.
Fleetguard Filters
Completed a new manufacturing plant in a location ravaged by rains in 8 months as against the industry standard lead time of over 12-14 months.
