Case Studies

Evidence, not opinion.

20 operational-excellence engagements from Gemba Concepts, and Gemba Connect's own digital transformation projects — every figure is what was actually recorded.

37% More Modules a Day, From the Same Plant

+37%

Solar PV Manufacturing

37% More Modules a Day, From the Same Plant

+58%

Composite Pipe Manufacturing

58% More Output from the Same Winding Lines

+123%

Packaging and Label Printing

OEE More Than Doubled in Twelve Months

+269%

Advanced Materials

Flow Revealed Capacity the Batch Was Hiding

Rs 15.24 Cr

Iron and Steel

Rs 15.24 Crore a Year, Found in Cost No One Was Watching

219 → 168

Food Processing

51 Roles Redeployed, Without Losing a Unit of Output

Rs 1.67 Cr

Textile

Rs 1.67 Crore a Year, from Staffing Decisions Made on Data

+197%

Locks Manufacturing and Ecommerce

197% More Storage, in the Same Four Walls

50,000 → 38,000

Industrial Packaging

Less Raw-Material Space, More Boxes per Shift

-68%

Ceramic Tiles

Two-Thirds Faster Turnaround, Same Building

5.6 → 12.2

Fashion Jewellery

Picking Productivity More Than Doubled

6.4 → 1.2 days

D2C Fashion

Carton-to-Rack, from 6.4 Days to 1.2

48% → 64%

Electrical Products Manufacturing

When Suppliers Miss, the Plant Pays for It

Rs 1.2 Cr

Artificial Leather

Rs 1.2 Crore a Year, Built Through Suppliers, Not Around Them

-30%

Construction

Procurement Lead Time Cut 30%, Across Every Site

+27%

FMCG Manufacturing

27% Better OTIF, Measured Before It Was Fixed

82.3% → 96.5%

Seasonal Retail

On-Time Fulfilment, from 82.3% to 96.5%

1,242 → 3,372

Industrial Valve Manufacturing

A Facility Designed for 2.7X the Output

Built to drawing

Packaging Manufacturing

A New Plant, Built Right the First Time and Commissioned on Schedule

+40%

Aluminium Rolling

40% Revenue Growth, from the Plant Already There

75%

ERP & AI Transformation

Sales & Inventory Digitization

80%

Warehouse & Order Digitization

Warehouse Management & Order Automation

60%+

ERP & Warehouse Digitization

ERP–WMS Transformation

80%

Supply Chain Transformation

Warehouse Management System (WMS) Implementation

70%

Sales & Customer Digitization

CRM System Implementation

100%

Specialty Chemicals | Finance Transformation

Batch-wise & Product-wise Costing

20%

Manufacturing Transformation

Production Digitization & Process Excellence

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