Step 1
Inventory Diagnosis
Identify hidden waste and cash blocksÂ
Practical, Measurable, and Sustainable Solutions by Greendot ConsultingÂ
Excess inventory is silent theft inside your business. Your profit is stuck in raw material, your cash is blocked in WIP, and your finished goods are waiting for a customer. Meanwhile, suppliers ask for payment, but you can’t raise invoices because material is lying idle—not moving.Â
This is a common struggle for mid-size manufacturers across India — and especially for manufacturing SMEs in Gujarat (Ahmedabad, Vapi, Surat, Vadodara, Rajkot, Ankleshwar) where we have delivered the largest share of our inventory reduction consulting projects. Whether you are in engineering, auto components, plastics, chemicals, pharma, or packaging — the root problem is the same: no inventory control system and no scientific planning methodology.
| Problem | Real Business Impact |
|---|---|
|
Raw Material Overload |
Blocked Working Capital |
|
High WIP |
Process chaos + delays |
|
Shortage despite high stock |
Expediting costs |
|
Wrong forecasting |
Frequent urgent purchases |
|
Supplier payment pressure |
No cash for business growth |
|
Warehouse overfilled |
Space shortage & risk |
|
Delivery delays |
Customer dissatisfaction |
|
Mixing MTO & MTS |
Zero clarity in planning |
| KPI | Measureable Outcomes |
|---|---|
|
Inventory Reduction |
30%-60% |
|
Working Capital Improvement |
25%-45% |
|
Lead Time Reduction |
20%-40% |
|
On-Time Delivery |
90% |
|
Space utlization |
+25% |
|
Cash Flow Strength |
Strong & predictable |
|
Team Planning Culture |
Built & sustained |
Outcome:Â Higher OEE, safer operations, improved productivity, and a workplace that runs like a well-oiled machine.Â
| Tool | How it helps |
|---|---|
|
ABC / FSN Analysis |
Identifies fast-moving vs dead stock and controls money leakage |
|
MRP & Material Planning |
Ensure right material at the right time – no excess, no shortage |
|
Kanban System |
Converts chaos into pull-based flow to reduce WIP |
|
Value Stream Mapping (VSM) |
Exposes bottlenecks that create excess inventory |
|
Safety Stock Calculation |
Eliminates guesswork in inventory decisions |
|
Make-to-order / Make-to-Stock Strategy |
Stops Overproduction to prevent pile-up |
|
Heijunka (Load Leveling) |
Balances stock accuracy and inventory control |
|
Warehouse Layout & 5S |
Increases space availability and visibility control |
|
Lead Time Reduction Tools |
Accelerates flow & reduces WIP holding |
Each tool is not theory—we implement it practically on your shop floor to reduce inventory and free cash stuck in the system.Â
In most plants we visit, 20–35% of inventory value is sitting as slow-moving or dead stock — material that hasn’t moved in 6 to 24 months but still occupies your warehouse, working capital, and management attention.
We solve this in three clear steps:
1. Identify — FSN (Fast, Slow, Non-moving) and ABC analysis on your live inventory data to surface every item that is genuinely dead vs. slow-moving vs. seasonal.
2. Liquidate — A practical disposal plan: re-engineer for current demand, return to supplier where possible, sell to secondary buyers, scrap recovery for raw material credit, or write-off with proper accounting.
3. Prevent — Tighten ordering rules, set MOQ discipline with purchase, fix forecasting gaps, and put a monthly dead-stock review on the management dashboard so it never builds up again.
Most clients recover ₹15–80 lakh in blocked working capital from dead stock alone within the first 90 days.
Inventory optimization is not the same as inventory cutting. The goal is to hold the right material, in the right quantity, at the right place — so service to the customer goes up while working capital comes down.
The techniques we apply on the shop floor and in your planning office:
– ABC and FSN classification to prioritise control where the money is
– EOQ and reorder-point optimization to remove guesswork in purchase
– Safety stock calculation based on actual demand and lead time variability — not gut feel
– Min-max and two-bin systems for low-value, high-frequency items
– Kanban-based pull replenishment for repetitive items
– Make-to-Order vs Make-to-Stock segmentation by SKU
– Lead time reduction with key suppliers, since shorter lead times directly reduce safety stock
– Heijunka load levelling to stop production from creating its own pile-up
Each technique is matched to your SKU type, demand pattern, and supply chain reality — not applied as a one-size-fits-all template.
Identify hidden waste and cash blocksÂ
Fix ordering system and production flowÂ
Implement KANBAN + reorder control
Balance operations and lead timeÂ
Daily inventory dashboard + target control
Greendot is one of India’s most trusted Lean & Productivity consulting partners, helping businesses grow through systematic and structured improvement.Â
Other consultants give documentation—we build systems that deliver business results.Â
Manufacturing Businesses in:Â
"Nirav has communication skills to get connected with hard working dedicated employees. He supports to bring each employee to visualize broad spectrum role. "
Atul Limited
"A person with who can create a roadmap to build strong value and take you to the next level "
MAAK & Associates
"Had a very good experience working with Greendot Consultancy, we have been resulted into skill improvement and develop personal view to grow our company and how to balance industry in many aspects. "
Alltech Industries
"Practical and Innovative way to resolve problems. Highly positive attitude. Implementation of suggested modification and changes is easier. "
Chiripal Polyfilms "Have been associated with Nirav's team, Green Dot for 2 years. These two years were quite focused on our objective and the goal set by the organization. Despite Covid lockdown we could achieve a successful milestone. Support extended by Nirav and team was just fantastic. Thanks Nirav, "
Atul Limited
"Nirav is an excellent Management Consultant. His company was appointed by our customer for Vendor Management Program, which included 5S and Lean Management practices. The program was quite effective. Later we engaged him for Strategic Management Program. This program is excellent and very effective. I recommend this program to companies who wants to take benefit from this.. "
Prima Automation (India) Pvt.Ltd
"I am working with greendot since last 12 + year. We are consistently improving our business process and Improved our productivity in paper mill and corrugation industries. In last couple of month we have increased our productivity by around 20% by implementing lean practice. Amazing productive experience with team greendot. They are the only consultant who can retain a client for this much duration and helping our industries to grow. "
RBR Papers LLP
"Nirav Trivedi is an excellent management consultant & coach. He and his team at Greendot has been helping multiple industries in improving productivity and reducing cost by training manpower to optimize processes and increase capacity of machines. I highly recommend his knowledge and expertise in this area. "
Accenture "Mr. Nirav Trivedi is an excellent coach both on personal and professional front. He has exceptionally curated his TQM course to identify gaps and increase productivity in sort span of time. I wish him and his team best of luck for all endeavors. "
Atul Limited "Mr. Nirav Trivedi is a excellent business consultant we have work with so far. His advice as a consultant has allowed our organisation to expand our business tremendously. He has helped us to implement changes in our policies and strategies that have made our organization more efficient and profitable. He is costliest among all the consultants, but WORTH IT ! "
Alltech Industries "We have worked with Mr Nirav Trivedi and Green Dot team for 5S implementation and journey is so good so far. 5S is not only house keeping improvement but it will help us in many other areas viz. productivity, inventory, money generation by identifying unwanted items, motivation and many more. "
Atul Limited
"Best in class Consultant for Business System development "
Shah Traders (Vapi)
"I personally Know Mr Nirav Since a Decade Now. Based on My professional experience & feedback from our a few common client of Cps Technologies & Green Dot, i can say Mr Nirav is having rich experience for management consulting in various Industry Verticles incl a working with out of India's clients, Practical approach in Problem Solving & creating A niche segment for his consulting by coaching , consulting & make client practice six sigma , lean management & etc. Techniques successfully. "
CPS Technologies
"Green Dot and NIrav Trivedi is very understanding on problems that organisation is facing and suggest remedies which suits to culture and receptiveness of employees to start off. On process improvement and setting best practices He delivers worth for company, particularly. We worked with him and satisfied with services he delivered. All the best and keep nurturing on. "
Rajhans Group of Industries
"I am enjoying with his consultation.if u want your business in automode i strongly recommend Mr Nirav Trivedi.i am in Automode r u? jaha apni soch bandh ho jati hai waha se unki soch suru hoti hai. Thank you Nirav Sir. "
Jalaram Khichdi
"Industry specific bull's eye approach with their expertise is an effective combination in Greendot's management, for industries to upgrade their operational standards... "
Sahajanand Valves
"Nirav, has worked with our Cluster for Lean Mfg implementation. He is constantly striving for excellence in his chosen domain and working hard towards his goal to taking Green Dot to the next level. Immense clarity of thought, good methodology for implementation across wide spectrum of Industries, keeping himself abreast with latest theories. He is a good orator and a good influencer. I highly recommend Nirav to those who are seeking business solutions for the better. "
RBD Engineers Pvt Ltd
"I know Nirav for many years, he is very committed to his work and his problem solving ability is his biggest asset. He always sets very high standards for him and his team which is difficult for others to match. Wish him all the best in future! "
Firmenich
"I know Nirav ji from last 5 years and I had learned a lot from him specially how to make consistent growth in career, excellent personality with in depth knowledge Truly it was Great experience to be connected with you....Thanks for being my connection "
Pacific Group of Companies
Very happy with Greendot's services and their support in continuous development of our organization. Over an year we have not only managed to keep our inventory under control, but also improved productivity. Our profit has increased , cost has minimized and we are currently able to utilize our capacity in very efficient manner. In addition to this, we have also managed to integrate all departments through one system. Greendot team members are very professional, always supportive, polite and have helped our employees adapt to change over a short period of time. Under the guidance of Mr. Trivedi's leadership and vision Greendot success is guaranteed.
Kingsley Ecotech Pvt Ltd
Very Professional on Management !
Hebei Yitaike Bearing Co.,Ltd - ETK Bearings
"He has immense and thorough knowledge of lean management, quality management system and backed by excellent academic. projects taken care by Nirajji is always hv a new experience and on time completion. "
JSW MI
"Good experience of having interacted with Mr. Nirav Trivedi. He delivered a motivational speech for undergraduate Chemical Engineering students at SCET during my tenure as Head of Chemical Engineering "
Sarvajanik College of Engineering & Technology
"Nirav is a good human being to work with and a highly professional management consultant. He has been instrumental in helping many organisations for course correction. wishing him all good things ahead. "
SEC GLOBAL CONSULTING AND INITIATIVES LLP "Most Reliable consultant, Bring our company to the next level now able to drive the company towards desire mission "
Jalaram Khichdi Very Professional on Management !
Hebei Yitaike Bearing Co.,Ltd - ETK Bearings
"Nirav has innovative thoughts and I like his management tips. "
Shreemad Rajchandra
"I would like to recommend Mr.Nirav Trivedi as a management consultant and productivity coach, Himal. "
HMC Sales
"Nirav is one of the most dynamic, versatile person i have ever came across in my professional career. He is one of the best management consultant we have in the whole Gujarat State. He has done some amazing assignments which resulted in huge cost savings , increased productivity for his clients and in some cases he along with his team managed to turn around the companies with their in depth knowledge of the subject matter. He & his team spends great amount of time to understand the root cause of the client & then they come up with the customised solution for them. I wish nirav & his team all the very best & i am sure nirav along with his team of green dot will create many more wonders in the corporate world with their expert knowledge. All the best nirav!! Keep doing the good stuff & keep helping the corporates to evolve & grow!! "
White Turtle Consulting and K&K Associate
"I was looking for an HR consulting firm and came across Nirav and his organization. Having worked with various consultants, I expected the same stuff but was pleasantly surprised to find his methods refreshingly different. Here was also a consultant who guaranteed a positive change... what could be more interesting? We are currently working with his firm and moving forward creating agents of change... Would definitely recommend him to anyone "
Vertellus Speciality Materials (India) Pvt.Ltd
"Nirav Trivedi is amazing person with great knowledge on team management and also with all the great ideas for growing own business with different tools to have faster and success. All completely solution for business for small and big business.. Amazing person with very down to earth and also ready to help everyone.. "
Imperial Overseas Education Consultants( Imperial Platforms Inc)
"I Know Nirav more the 20 years , he is Master of Management !! Keep it up "
Indobuilt Storage System Pvt.Ltd
"Superb insight in Small Business operations. Good at decoding SME bottlenecks. Polite service of the entire Organisation. Very well Read. Recommended for Management Consulting "
Usha Die Casting INDS
"Nirav & his Tem@ GreenDot Effectively Practices Trade as a Consultant to Various Small to Enterprise Organizations with ease , be it Improving Profitability, Brand Image, HR , Productivity, Efficiency & as team an asset to get associated with ! "
Matrix Network and Solutions
"Good 5s consultant "
Agarkar HR Services Pvt Ltd
"I highly recommend Mr.Nirav for his his professionalism and result oriented approach. "
Yashaswi Consultants
Unlock the potential of your business with data-driven strategies. We help you streamline operations, improve profitability, and reach the top of position your company.
© 2026 Greendot Management Solutions | All Rights Reserved | Developed by Kartikjh
"Better Consulting option for MSMEs "
Meera Industries Limited Independent Director