Case Study Archives - Greendot Management Consultancy

Value Engineering Case Study: Reducing Life-Cycle Costs in Heavy Industrial Hydraulic Systems

Executive Summary This case study examines how a leading Indian heavy engineering manufacturer (referred to as “Company A” due to NDA restrictions) applied Value Engineering (VE) methodology to reduce the life-cycle costs of hydraulic actuation systems for specialized industrial equipment. Through systematic function analysis and creative problem-solving, the VE team achieved a 23% reduction in

Transforming AeroBlue Footwear: How Lean Manufacturing Delivered a 20% Boost in Productivity and Faster Delivery

Achieved 20% Higher Productivity and 30% Faster Deliveries by Eliminating Production Bottlenecks through Lean Manufacturing Client Overview Challenges (Before Greendot) DAeroBlue Footwear faced multiple inefficiencies across its production operations: Our Approach Greendot designed a phased Lean implementation roadmap tailored for the footwear industry: Solutions Implemented Area Solution Workplace Organization Employee feedback loop and regular Lean

81% Faster Delivery and 50% Fewer Rejections: How R.S. Automation Transformed Efficiency through Lean Manufacturing

Reduced Delivery Lead Time by 81% and Cut Rejections by 50% through Lean Manufacturing and Continuous Improvement Culture Client Overview Challenges (Before Greendot) Despite its technical expertise and strong customer base, R.S. Automation Transformed faced significant operational inefficiencies: Our Approach Greendot developed a customised Lean Manufacturing Implementation Plan focused on productivity improvement, waste reduction, and

70% Fewer Accidents, 25% Higher Productivity: How RBD Engineers Saved 30 Lakhs through Lean Safety & Space Optimization

Reduced Workplace Accidents by 70% and Improved Productivity by 25% through Lean-Based Safety and Space Management Transformation Client Overview Challenges (Before Greendot) RBD Engineers faced dual challenges affecting both safety performance and production efficiency: Our Approach Greendot designed a Lean Manufacturing Implementation Program combining safety, layout optimisation, and visual management for measurable results: Continuous Monitoring:

15% More Machine Power, 20% Less Waste: How Powerful Industries Boosted Efficiency through Lean Manufacturing

Increased Machine Productivity by 15% and Reduced Rejection Rate by 20% through Lean Manufacturing and Kaizen Initiatives Client Overview Challenges (Before Greendot) Despite decades of experience, Powerful Industries was facing production inefficiencies that limited growth and profitability: Cultural Resistance: Employees were hesitant to adopt change or take ownership of improvement initiatives. Our Approach Greendot implemented

25% Less Downtime, 30% More Space: How Packwell Industries Boosted Efficiency through Lean Manufacturing

Reduced Machine Downtime by 25% and Optimized 30% Factory Space through Lean Manufacturing Transformation Client Overview Challenges (Before Greendot) Packwell faced critical operational challenges that affected production flow and on-time deliveries: Our Approach Greendot developed a structured Lean Manufacturing Implementation Plan focusing on waste elimination, workplace organization, and data-driven decision-making: Solutions Implemented Area Solution Equipment

90% Less Waste, 40% More Sales: How Jalaram Khichdi Transformed Its Restaurant Operations through Effective Management Consulting

Reduced Food Waste by 90% and Increased Sales by 40% through Leadership Development and Process Optimization Client Overview Challenges (Before Greendot) Jalaram Khichdi faced deep-rooted management and operational inefficiencies that were impacting profitability and morale: Our Approach Greendot implemented a comprehensive Management Consulting program focusing on leadership development, process improvement, and culture transformation: Solutions Implemented

One Day Faster: How FCG Hi-Tech Cut Assembly Time by 30% and Improved Production Efficiency by 50% through Lean Manufacturing

Reduced Assembly Time from 3 Days to 1 Day and Boosted Production Efficiency by 50% through Lean Implementation Client Overview Market Presence: A reputed Indian brand with decades of expertise in manufacturing and supplying high-precision electrical products to global markets. Challenges (Before Greendot) FCG Hi-Tech struggled with operational inefficiencies that affected customer commitments and profitability:

Lean’s Impact on the Bottom Line: How Eris Lifesciences Achieved ₹2.4 Crore Annual Savings Through Lean Transformation

Reduced Changeover Time by 50%, Boosted Productivity by 20%, and Saved 2.4 Crore Annually through Lean Transformation Client Overview Challenges (Before Greendot) Eris Lifesciences faced critical operational challenges affecting capacity, cost, and efficiency: Unmonitored Lead Time: No Value Stream Mapping (VSM) system to track production flow and identify bottlenecks. Our Approach Greendot’s transformation roadmap for

Revolutionising Production Lead Time: How DG Industries Reduced Lead Time by 78% and Increased Sales by 30% through Lean Transformation

Reduced Production Lead Time from 29 Days to 9 Days and Increased Sales by 30% through Lean Manufacturing and Kaizen Culture Client Overview Challenges (Before Greendot) Despite a strong market reputation, DG Industries faced process inefficiencies that limited scalability and responsiveness: Weak Organizational Culture: Low employee engagement, teamwork gaps, and resistance to change slowed innovation.

Case Study – Greendot Consulting – COPTEC

Achieved ₹2.8 Billion Annual Cost Savings and 60% Production Growth by Transforming Low OEE Operations into a Data-Driven Lean System Client Overview Challenges (Before Greendot) Ashwin Auto Cast faced recurring production inefficiencies that affected cost and delivery performance: Our Approach Greendot designed a structured Lean roadmap tailored for automotive component manufacturing: Solutions Implemented Results Achieved

New India Cuprotec – From Downtime to Data-Driven Excellence

Achieved 75% Improvement in Operational Efficiency and Boosted Daily Production from 15 to 27 Tons by Implementing Data-Driven Lean Systems Client Overview Â· Industry: Copper Extrusion & Conductivity Products Â· Location: Gujarat, India Â· Employees: 250+ Â· Products/Services: High-Conductivity Electrolytic Copper Rods, Wires & Customized Copper Components Â· Certifications: ISO 9001, ISO 14001, ISO 45001,

Lean and Mean: How Ashwin Auto Cast Increased Production by 20% and Reduced Costs by 30% through Lean Transformation

Achieved 20% Higher Production, 30% Lower Maintenance Cost, and 15% Inventory Reduction through Lean Manufacturing Client Overview Challenges (Before Greendot) Ashwin Auto Cast faced recurring production inefficiencies that affected cost and delivery performance: Our Approach Greendot designed a structured Lean roadmap tailored for automotive component manufacturing: Solutions Implemented Area Solution Workplace Organization 5S methodology to