Author
Mohit Bafna
Co-Founder of Gemba Concepts, trained in the Toyota Production System.
About Mohit Bafna
Co-Founder, Gemba Concepts
Mohit Bafna founded Gemba Concepts in 2014 and shapes how the firm works: diagnose the real problem, implement the change alongside the client's own team, and stay accountable until the operation is stable.
That practitioner, execution-first approach now runs across engagements in India, the Middle East and Africa, in more than 40 sectors.
He writes about what actually breaks operations on the shop floor — material planning, inventory accuracy, scrap and rework, production flow — and what fixes it, drawing on Gemba Concepts' own engagements.
Writes about
- Operational excellence
- Lean manufacturing
- Toyota Production System
- Inventory management
- Material planning
- Production planning
- Scrap and waste reduction
Articles by Mohit Bafna
13 articles, newest first
How to Improve Production Planning and Reduce WIP in Printing & Packaging Manufacturing
Printed sheets waiting for lamination, laminated reels waiting for slitting, die-cut blanks waiting for gluing. Everything's moving. Nothing's finishing.
How to Prevent Raw Material Shortages and Production Delays in Printing & Packaging Manufacturing
The press is ready. The job is scheduled. The customer is waiting — and the board hasn't arrived. What looks like a raw material shortage is often a visibility or planning problem in disguise.
How to Reduce Scrap, Material Waste and Rework in Personal Hygiene Manufacturing
Nonwoven trimmings. SAP overshoot. Wet wipes rejected for saturation variance. Every one is material that was paid for, processed, sometimes packed, and then written off.
Inventory Management in Personal Hygiene Manufacturing: How to Reduce Shortages, Excess Stock and Production Delays
Sanitary pads short while adult diaper cartons block the aisles. Handwash pumps missing while lotion caps arrive in triplicate. The pattern is familiar — the costs are not always visible.
How to Reduce Batch-to-Batch Production Time in Pharmaceutical Manufacturing
The previous batch is finished. The equipment is ready. So why hasn't the next one started? The answer is rarely one big problem — it's small gaps in cleaning, materials, and clearance that add up.
What Pharma Consultants See Between Batches, That Plants Often Miss
The next batch started at two o'clock on Monday afternoon. Sixty-four hours had passed since the last one ended — and only part of that was ever required.
How Pharma Manufacturers Can Get Real-Time Visibility with ERP Software
It is 3:40 PM. A batch is running on Line 2, but the production manager still needs to walk to the shop floor for an update. Everyone is working — but the complete picture is still hard to find.
Hidden Costs in Cable & Wire Manufacturing: Where Plants Lose Money
A cable plant can be busy all day — machines running, operators working, orders moving — and still lose money. The losses hide in small, repeating problems, not one big one.
How to Reduce Scrap in Wire & Cable Manufacturing
The scrap bin tells you how much you lost. It rarely tells you where the loss began — and by the time material reaches it, the copper, aluminium, insulation, and machine time are already gone.
How to Increase Wire & Cable Production Capacity Without Buying New Machines
Before you sign off on a new line, one uncomfortable question — how much of the capacity you already paid for are you quietly throwing away every shift?
How Tile Manufacturers Cut Truck Turnaround Time in Half
Learn how better dispatch planning, material readiness and yard visibility can help tile manufacturers reduce truck waiting time.
Restaurant Operations Management for Growing Gourmet Food Brands with Multiple Outlets
Your first outlet was a hit. Can every outlet after it feel the same? A practical guide to the SOPs, staff training, and feedback systems that keep quality consistent as you scale.
How to Deliver the Same Premium Pizza at Every Outlet
Your best dough handler goes on leave for two weeks. Does outlet #12 still turn out the same crust? A practical restaurant SOP and quality-control framework for multi-outlet pizza brands.
Industrial Businesses Across 3 Continents