Success stories

  • Equipment Manufacturing

    Kirloskar Oil Engines Ltd. (KOEL)

    After moving away from forecast-based to consumption-based operations, the company now offers guaranteed deliveries in one week.

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  • Equipment Manufacturing

    Lakshmi Machine Works Ltd. (Machine Tool Division)

    After implementing an end-to-end 'pull' replenishment solution, the company ensured timely assembly of standard machines

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  • Equipment Manufacturing

    Godrej Material Handling

    In a few months of implementation, manufacturing lead-times crashed to one-third

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  • Equipment Manufacturing

    Kirloskar Oil Engines Ltd (Spares And Services)

    After implementation availability of spares at service points increased to 96% while overall inventory fell by 49%

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  • Equipment Manufacturing

    Godrej Securities Solutions

    Within two years of implementation, profits tripled, and then quadrupled in the third year

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  • Equipment Manufacturing

    Bajaj Luminaires Division

    The on time in full delivery performance of the firm improved to 85% (industry standard is 20-30%)

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  • Equipment Manufacturing

    Godrej Storage Solutions

    A new supply chain segment was created for supplying standard products with three-day guaranteed delivery

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  • Equipment Manufacturing

    Filtrum Tools

    The company reduced overall lead-time by 25%, and improved on-time delivery performance to about 90%

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  • Equipment Manufacturing

    Hercules Hoists Limited

    After TOC implementation, the overall profitability improved along with other operational and financial parameters

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  • Equipment Manufacturing

    Godrej Tooling

    On-time delivery of ETO projects improved to 85%; overall lead-time shrank

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  • Auto & Auto Components

    Ashok Leyland- Spares Parts Division

    The company transformed its spares supply chain within 15 months of implementing the ‘pull’ replenishment model of TOC

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  • Auto & Auto Components

    Tata Motors-Spare Parts & Services Division (Commercial Vehicles)

    While the daily availability of parts increased from 75% to 93%, inventory levels reduced from 67 days to five days!

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  • Auto & Auto Components

    Fleetguard Filters Pvt Ltd

    After a company-wide implementation of TOC, the company enjoyed a CAGR of 25% in the last 10 years

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  • Auto & Auto Components

    J.K. Fenner (India) Ltd

    J.K Fenner has transformed its operations by providing higher availability (>90%) of its products as well as faster and reliable delivery (98%)

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  • Auto & Auto Components

    Kirloskar Ferrous Industries Ltd (KFIL)

    The company’s customer on-time delivery increased to 100% on daily basis and significantly increased SOB with key customers

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  • Auto & Auto Components

    Lucas Indian Service Ltd.

    Same-day order fill rate of the firm improved from 50% to 80%; distributors’ sales grew by 45%

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  • Auto & Auto Components

    Mahindra First Choice Services

    With a year, turnaround time reduced to 58% and the revenue generated per work hour increased by 91%

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  • Auto & Auto Components

    Tata Radiators

    The implementation of the TOC flow Management solution in NPD has doubled the output rate of new products.

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  • Auto & Auto Components

    Top1 Lubricants, Indonesia

    This Indonesian company reduced its inventory from seven months to two months while improving availability to near 100%

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  • Auto & Auto Components

    Fleetguard Filters Pvt. Ltd. (NPD)

    In addition to reduction in stress levels of people, Productivity improved three times & iterations reduced by more than half

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  • Auto & Auto Components

    Filtrum Polymers

    In the first six months of implementation itself, the firm released more than 60% additional capacity and improved inventory turns by 50%

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  • Auto & Auto Components

    Mahindra First Choice (Spares And Services)

    Without any offering schemes or discounts this young company increased average daily sales by 1275%

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  • Consumer Goods & Retail

    Godrej Interio-NPI

    Until recently the company was struggling to complete projects on time but within one year of TOC implementation, lead-times crashed

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  • Consumer Goods & Retail

    Bajaj Electricals Limited (CP)

    The consumer products division of the company which includes small appliances, fans and lighting, accounts for 50% of the top line

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  • Consumer Goods & Retail

    VIP Industries Ltd

    Not only did the stock availability increase to more than 90%, the company also saw its own stores grow by 20%

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  • Consumer Goods & Retail

    Godrej Megasari

    The company’s largest modern trade partner dramatically reduced its inventory (41%) while improving availability to a 98-100%

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  • Consumer Goods & Retail

    Parag Milk Foods Ltd.

    They experienced a 56% increase in average sales per day & 200% jump in outlets billed after adopting TOC

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  • Consumer Goods & Retail

    Godrej Interio-Home Kitchens

    With implementation of TOC operations solutions, the ex-factory OTIF performance has gone up from around 50% to 98%

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  • Consumer Goods & Retail

    Liberty Shoes Ltd

    The company has achieved over 97% availability in its central warehouse, probably amongst the best in the fashion industry

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  • Consumer Goods & Retail

    Godrej Interio- Service And Spares

    Service levels improved (complaints reduced by 55%) by process improvement & without increasing the fixed cost

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  • Consumer Goods & Retail

    JK Files And Tools

    Using TOC solutions, JK tools increased output by 30% from existing capacity within six months of implementation

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  • Consumer Goods & Retail

    Landmark

    The company put in place robust mechanisms to effectively manage its portfolio and its product mix in stores

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  • Consumer Goods & 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 30%

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  • Consumer Goods & Retail

    Godrej Interio

    In addition to crashing lead-time of regular orders, the company now also offers an assured seven days delivery

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  • Engineering & Construction

    KEI Industries Ltd

    Post TOC implementation, the company reduced lead-time of total project execution and improved working capital rotations by enhancing flow of projects.

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  • Engineering & Construction

    Bajaj Electricals Engineering And Projects Division

    With the new paradigm of synchronized supply and execution management, the company now delivers projects 3-4 months early

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  • Engineering & Construction

    Godrej PIRE

    The company adopted the TOC method of planning and executing projects to consistently complete projects in time & thus turnaround the company

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  • Engineering & Construction

    Tata Bluescope Steel Limited

    Lead-time of projects reduced by 25%; manufacturing output increased by 15%; engineering resources output increased by 30% post TOC

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  • Engineering & Construction

    Tata Metaliks

    The blast furnace shut down was completed well within budget (87%) and in a record of 23 days

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  • Engineering & Construction

    Fleetguard Filters

    The firm built a new plant in a rain ravaged location in eight months (industry standard lead-time of over 12-14 months)

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  • Engineering & Construction

    Trident

    Adopting TOC principles, the company erected a spinning plant of 30,000 spindles, in a record time of 9 months

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  • Textile & Garments

    Pratibha Syntex Ltd

    This integrated textile company saw its OTIF increase to 90% and profits go up by 55% after adopting TOC

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  • Textile & Garments

    Raymond Luxury Cottons Ltd.

    Within eight months of implementing TOC, production lead-time reduced by 25%; OTIF improved to 95%

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  • Textile & Garments

    A Major Vertically Integrated Linen Exporter

    After adopting TOC "pull" manufacturing, this company was able to able to improve OTD to 95% from earlier 30%!

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