Raymond Luxury Cottons Ltd.
Within eight months of implementing TOC, production lead-time reduced by 25%; OTIF improved to 95%
Textile & Garments
High Velocity Custom Manufacturing
The company is a leading shirting fabric manufacturing company and part of Raymond Group. The objective of this assignment is to build a decisive competitive edge of high reliability on delivery performance at SO level by reducing the production lead-time, and to capitalize the same in the market to increase company sales and profits. By implementing TOC solutions, Raymond Luxury Cottons Ltd. has got the following benefits within a short span of eight months.
Before TOC, production flow entity used to be at SKU level leading to desynchronized flow at SO level and more waiting time at warehouse. (First SKU waiting for the last SKU). After TOC, the production flow entity has been changed to SO level. A 50% reduction (15 days to seven days) in assortment waiting time at company warehouse has been achieved because of improved synchronization and flow. This reduction also results to improved cash-to-cash cycle.
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Other Case Studies
Kirloskar Oil Engines Limited-NPD
By focusing on enabling flow of projects in NPD funnel using TOC principles, KOEL crashed lead time of
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Godrej Interio Healthcare
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Godrej Material Handling
Within a few months of implementation, manufacturing lead-times crashed to
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Bajaj Luminaires Division
The on time in full delivery performance of the firm improved to 85% (industry standard is
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Schneider Electric
After the company adopted the TOC flow model for software development, productivity increased by a whopping
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Kirloskar Oil Engines Ltd. (KOEL)
After moving from forecast-based to consumption-based operations, the company now offers guaranteed deliveries in one
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Godrej Securities Solutions
Within two years of implementation, profits tripled, and then quadrupled in the third
High Velocity Custom Manufacturing
Godrej Storage Solutions
A new supply chain segment was created for supplying standard products with three-day guaranteed
High Velocity Custom Manufacturing
Kirloskar Oil Engines Ltd (Spares And Services)
After implementation, availability of spares at service points increased to 96% while overall inventory fell by
Solution for Spares & Services
Godrej Tooling
On-time delivery of ETO projects improved to 85%; overall lead time
High Velocity Custom Manufacturing
Action Construction Equipment Limited - ACE Cranes
Leading material handling, construction equipment manufacturing company
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Lakshmi Machine Works Ltd. (Machine Tool Division)
A TOC based flow manufacturing solution was implemented to ensure on time delivery as per committed due
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Raychem RPG
A joint venture between TE connectivity and RPG Group, it is market leader in innovative energy & hydrocarbon solutions
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Filtrum Tools
The company reduced overall lead-time by 25%, and improved on-time delivery performance to about
High Velocity Custom Manufacturing
GMM Pfaudler Ltd
It is a leading supplier of critical process equipment and systems to the global chemical and pharmaceutical
High Velocity Custom Manufacturing
Hercules Hoists Limited
Production was streamlined by implementing Theory of Constraints based on “pull” manufacturing
High Velocity Custom Manufacturing
+ 1
Sales Productivity Enhancement
LMW Machine Tool Division (MTD)-New Product Development
After implementation of TOC, lead times for NPD crashed and contribution of new products to sales increased three times
Rapid Flow R&D
L&T – Heavy Engineering
Makes engineered to-order equipment for process industries such as fertilizer, chemical, refinery,
High Velocity Custom Manufacturing
Jakson
A diversified energy and infrastructure company having expertise in distributed energy, solar and electrical EPC
High Velocity Custom Manufacturing
+ 2
Pull Manufacturing & Distribution
Sales Productivity Enhancement
Shanthi Gears
Makes a wide range of industrial power transmission products including gears and gear
High Velocity Custom Manufacturing
Greaves Cotton Ltd.
Manufacturers of diesel/petrol engines, farm equipment and
High Velocity Custom Manufacturing
PARI
Develops and provides automation solutions using world class robotic products and technologies
Rapid Flow R&D
Badve Engg
Manufacturer of two-wheeler frames, two-wheeler chassis, crossmember, four-wheeler chassis, three-wheeler chassis etc
High Velocity Custom Manufacturing
International Tractors Limited
After implementing TOC, the company ensures near-perfect availability of components and tractors while reducing
High Velocity Custom Manufacturing
+ 2
Rapid Flow R&D
Solution for Spares & Services
Ashok Leyland- Spares Parts Division
Post implementing the TOC distribution model, the company’s spares business continued to grow at over 25%
Pull Manufacturing & Distribution
Tata Motors-Spare Parts & Services Division (Commercial Vehicles)
After implementation, the daily availability of spare parts increased from 75% to 93%, & inventory reduced from 67days
Pull Manufacturing & Distribution
+ 1
Solution for Spares & Services
Ashok Leyland – NPD
More than a year of implementation, company could streamline its transition from BS4 to BS6 but increased output of BS4
Rapid Flow R&D
Fleetguard Filters Pvt Ltd
After a company-wide implementation of TOC, the company enjoyed a CAGR of 25% in the last ten
High Velocity Custom Manufacturing
JK Fenner (India) Ltd
JK Fenner transformed its operations by providing higher availability (>90%) of its products as well as faster and
High Velocity Custom Manufacturing
+ 1
Pull Manufacturing & Distribution
Kirloskar Ferrous Industries Ltd (KFIL)
The company’s customer on-time delivery increased to 100% daily and significantly increased SOB with key
High Velocity Custom Manufacturing
+ 1
Rapid Flow R&D
Lucas Indian Service Ltd.
Same-day order fill rate of the firm improved from 50% to 80%; distributors’ sales grew by
Pull Manufacturing & Distribution
+ 1
Solution for Spares & Services
Mahindra First Choice Services
Within a year, turnaround time reduced to 58% and the revenue generated per work hour increased by
Pull Manufacturing & Distribution
Mahindra First Choice (Spares And Services)
Without any offering schemes or discounts, this young company increased average daily sales by
Solution for Spares & Services
Tata Radiators
The implementation of the TOC flow management solution in NPD has doubled the output rate of new
Pull Manufacturing & Distribution
Fleetguard Filters Pvt. Ltd. (NPD)
In addition to the reduction in stress levels of people, productivity improved three times and reduced iterations by
Rapid Flow R&D
Filtrum Polymers Pvt. Ltd.
In the first six months of implementation, the firm released more than 60% additional capacity, and improved inventory
High Velocity Custom Manufacturing
Royal Enfield
A global leader in the mid-sized motorcycle
Solution for Spares & Services
TVS Motor Company Ltd
The third largest two-wheeler manufacturer in
Pull Manufacturing & Distribution
+ 2
Rapid Flow R&D
Solution for Spares & Services
SKF
A leader in providing automotive and industrial engineered solutions through its five technology-centric platforms:
Pull Manufacturing & Distribution
Volvo Eicher
A joint venture between Volvo Group and Eicher Motors for manufacturing commercial vehicles in
Pull Manufacturing & Distribution
+ 1
Solution for Spares & Services
Tata Autocomp Systems Ltd
Part of Tata Motors, distributes commercial vehicles and spare parts in South
Pull Manufacturing & Distribution
Shriram Pistons
Largest manufacturer and exporter of pistons and rings from
High Velocity Custom Manufacturing
Aditya Auto
A specialized automotive supplier of mechatronic systems, precision components and motors with capabilities spanning
High Velocity Custom Manufacturing
ASK Automotive
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Blackberrys
A premium brand in men's apparel and
Pull Manufacturing & Distribution
+ 1
Solution for Retail
Pratibha Syntex Ltd
This integrated textile company saw its OTIF increase to 90% and profits go up by 55% after adopting
High Velocity Custom Manufacturing
Raymond Luxury Cottons Ltd.
Within eight months of implementing TOC, production lead-time reduced by 25%; OTIF improved to
High Velocity Custom Manufacturing
A Major Vertically Integrated Linen Exporter
After adopting TOC "pull" manufacturing, this company was able to improve OTD to 95% from earlier
High Velocity Custom Manufacturing
Raymond
Manufacturer of suiting
High Velocity Custom Manufacturing
+ 2
Pull Manufacturing & Distribution
Sales Productivity Enhancement
Trident Group (Home Textiles)
A major manufacturer and exporter of textiles
High Velocity Custom Manufacturing
Dollar Industries
A leading producer of fashion innerwear, loungewear, gym wear, sleepwear and track suits
Pull Manufacturing & Distribution
+ 1
Sales Productivity Enhancement
Arvind Fashions
A leading lifestyle company with a dynamic portfolio of over 27 global brands in
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+ 1
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Dr. Reddy’s Laboratories
Manufactures and markets a wide range of pharmaceuticals in India and
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Lupin
It is one of the largest generic pharmaceutical companies by revenue
Rapid Flow R&D
Sun Pharma
Manufacutres and markets > 300 APIs, to customers in over 100 countries across the
High Velocity Custom Manufacturing
Ajanta Pharma
A company engaged in development, manufacturing and marketing of quality finished drugs in domestic and international
High Velocity Custom Manufacturing
Strides
A specialty pharmaceutical company engaged in development, manufacturing of generic pharma
High Velocity Custom Manufacturing
Bajaj Electricals Engineering And Projects Division
With the new paradigm of synchronized supply and execution management, the company now delivers most projects 3-4
Rapid Projects Execution
Godrej Electricals & Electronics Division
The company adopted TOC method of planning and executing projects to consistently complete projects in time
Rapid Projects Execution
Skipper Limited
India's largest power transmission & distribution (T&D) structure manufacturing
High Velocity Custom Manufacturing
+ 1
Rapid Projects Execution
KEI Industries Ltd
The company used flow principles of TOC to seamlessly align purchase/material delivery to site requirements to speed up
Rapid Projects Execution
Tata Bluescope Steel Limited
Lead time of projects reduced by 25%; manufacturing output increased by 15%; engineering resources output increased by
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Tata Metaliks
The blast furnace shut down was completed well within budget (87%) and in a record of 23
Rapid Projects Execution
Fleetguard Filters
The firm built a new plant in a rain ravaged location in eight months (industry standard lead-time of over 12-14
Rapid Projects Execution
Trident Group
Adopting TOC principles, the company erected a spinning plant of 30,000 spindles, in a record time of nine
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Godrej Security Solutions
Within two years of implementation, profits tripled, and then quadrupled in the third
High Velocity Custom Manufacturing
+ 1
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Sterlite Technologies Ltd.
Global technology leader that designs, builds and manages smarter digital
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Godrej Interiors
A business unit of Godrej Interio, it designs and executes interiors of commercial
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Godrej AV
Leading audio visual solutions provider for applications such as boardrooms, conference rooms, auditoriums, training
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Salasar Techno Engg.
A company offering customers one-stop shop for engineering, designing, procurement, fabrication, galvanization and
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Godrej Interio-NPI
Until recently the company was struggling to complete projects on time but within one year of TOC implementation,
Rapid Flow R&D
Bajaj Electricals Limited (CP)
With an objective of increasing sales by addressing sales lost due to unavailability, the company adopted TOC
Pull Manufacturing & Distribution
+ 1
Rapid Flow R&D
VIP Industries Ltd
Not only did the stock availability increase to more than 90%, the company also saw its own stores grow by
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+ 1
Solution for Retail
Jindal Stainless Limited
Production transitioned from MTO to “pull” replenishment-based MTA for nearly 1,000 SKUs (~70% of total
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Godrej Megasari
The company’s largest modern trade partner dramatically reduced its inventory (41%) while improving availability to a
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Parag Milk Foods Ltd.
They experienced a 56% increase in average sales per day and 200% jump in outlets billed after adopting
Sales Productivity Enhancement
Walkaroo International
Within a year, new product output improved by 75% and availability at plant warehouse reached
Pull Manufacturing & Distribution
+ 1
Rapid Flow R&D
Godrej Interio-Home Kitchens
With implementation of TOC operations solutions, the ex-factory OTIF performance has gone up from around 50% to
Pull Manufacturing & Distribution
Liberty Shoes Ltd
The company has achieved over 97% availability in its central warehouse, probably amongst the best in the fashion
Pull Manufacturing & Distribution
JK Files And Tools
Using TOC solutions, JK tools increased output by 30% from existing capacity within six months of
High Velocity Custom Manufacturing
Godrej Interio- Service And Spares
Service levels improved (complaints reduced by 55%) by process improvement & without increasing the fixed
Solution for Spares & Services
Landmark
The company put in place robust mechanisms to effectively manage its portfolio and its product mix in
Solution for Retail
Liberty Retail Revolution Ltd
Within a year, the company improved the store inventory cover from 10 months to five months, while increasing sales by
Solution for Retail
Godrej Interio - office furnitures
In addition to crashing lead-time of regular orders, the company now also offers an assured seven days
High Velocity Custom Manufacturing
+ 2
Pull Manufacturing & Distribution
Sales Productivity Enhancement
MSP Steel
An integrated steel plant with a wide range of products including bars, pellets, sponge iron, ferro alloys, billets,
High Velocity Custom Manufacturing
Skipper Pipes Limited
Manufacturers plumbing fixtures (UPVC, CPVC and SWR pipes and fittings) and agricultural solutions (rigid pipes and
Pull Manufacturing & Distribution
+ 1
Sales Productivity Enhancement
Pidilite
A market leader in adhesive, industrial and construction chemicals, and art material. Leading brands include Fevicol, M
High Velocity Custom Manufacturing
+ 1
Pull Manufacturing & Distribution
Sintex Industries Limited
Leader in plastic processing products like panel tanks, PVC doors
Pull Manufacturing & Distribution
Century Plyboards India Ltd.
Manufactures, sells and exports plywood and
Pull Manufacturing & Distribution
+ 1
Sales Productivity Enhancement
Asian Granito
Manufacturer of various kinds of tiles including vitrified tiles, ceramic tiles, wall tiles and agglomerated marble
Pull Manufacturing & Distribution
APL Apollo Tubes Limited (APL Apollo)
Leading manufacturers of branded steel products
High Velocity Custom Manufacturing
Vaibhav Global Limited
Manufacturer and exporter of fashion jewellery and lifestyle
High Velocity Custom Manufacturing
Kirloskar Agri
Manufacturers of diesel engines and agricultural pump
High Velocity Custom Manufacturing
+ 1
Pull Manufacturing & Distribution
Shakti Pumps
India’s leading manufacturer of energy efficient submersible
Pull Manufacturing & Distribution
Westside
Part of Trent Ltd, it is a leading brand in lifestyle and apparel retail
Solution for Retail
Viveks
Leading consumer electronics and home appliances retail chain in
Solution for Retail
Godrej Hershey’s
Manufactures and distributes food and
Pull Manufacturing & Distribution
Future Retail Ltd
The fashion arm of Big Bazaar offering apparel for men, women and kids
Solution for Retail
Yellow Diamond (Prataap Snacks)
Prataap Snacks, under the brand name Yellow Diamond, is one of the leading manufacturers and distributors of chips and
Pull Manufacturing & Distribution
+ 1
Sales Productivity Enhancement
Kurl-on
India's leading brand of mattresses, furniture and furnishing
Pull Manufacturing & Distribution
Daawat
Leading brand in India offering premium and finest grains of basmati
Pull Manufacturing & Distribution
+ 1
Sales Productivity Enhancement
Shalimar Paints
One of India's oldest paint manufacturing companies
Pull Manufacturing & Distribution
Polycab
Manufactures and sells cables, wires and electrical
High Velocity Custom Manufacturing
+ 1
Pull Manufacturing & Distribution
Kelloggs
World's leading cereal company; second largest producer of crackers and savory
Pull Manufacturing & Distribution
Linc pens
A well known writing instrument manufacturer with a national and international
Pull Manufacturing & Distribution
+ 1
Sales Productivity Enhancement
Lenskart
One of India's fastest growing eyewear
Pull Manufacturing & Distribution
+ 1
Solution for Retail
Jindal Stainless Steelway
Company processes and distributes cut-to-size polished stainless steel sheets, coils and banks to
High Velocity Custom Manufacturing
+ 1
Pull Manufacturing & Distribution
Bake with Yen
It specializes in the manufacture, supply & distribution and retail of baking ingredients, premixes, accessories and
Pull Manufacturing & Distribution
+ 1
Solution for Retail
Luminous Power Technologies Pvt. Ltd
It is a leading power and home electrical specialist providing power backup solutions, solar solutions, and home
Pull Manufacturing & Distribution
TI Cycles of India Ltd
The company is a market leader in plastic pipes &
Pull Manufacturing & Distribution
Ambuja Cements
It is a leading cement companies in India known for its hassle-free, home-building solutions.
Pull Manufacturing & Distribution
TATA International
A global trading and distribution company
High Velocity Custom Manufacturing
TATA Steel
It is the world’s second-most geographically diversified steel
High Velocity Custom Manufacturing
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Registered Office:
Vector Management Consulting Pvt. Ltd.
10th floor, Thane One, DIL Complex,
Ghodbunder Road, Majiwada,
Thane (West), Maharashtra - 400610, India.
Vector Management Consulting Pvt. Ltd.
10th floor, Thane One, DIL Complex,
Ghodbunder Road, Majiwada,
Thane (West), Maharashtra - 400610, India.