Outsourced Accounting, Bookkeeping, Taxes & Payrol
250%
annually
Average ROI
28%
annually
Increase revenue
Operations That Deliver Perform Scale
Inventory
- Capital blocked in excess and slow-moving stock.
- Space constraints, obsolescence, and working capital pressure
Our Solution
- Lean inventory design and Gemba-based audits to release stuck capital
- Improve inventory turns.
- Stabilize cash flow.
Lead Time
- Long, unpredictable delivery cycles
- Missed commitments
- Lost customer confidence
Our Solution
- Value stream mapping and Time & Motion studies to identify bottlenecks
- Remove waiting time
- Compress lead times.
Productivity
- Output not matching manpower & cost.
- Founders and Senior leaders pulled into daily firefighting.
- Operations dependent on people, not systems.
Our Solution
- Root cause analysis at the point of work.
- Quality-at-source practices.
- Process controls that prevent defects before they occur.
Quality
- Rework, returns, and inconsistent output Margin erosion and brand risk
Our Solution
- Root cause analysis at the point of work
- Quality-at-source practices
- Process controls that prevent defects before they occur.
P&L Pressure
- Costs rising faster than revenue.
- Margins shrinking despite growth.
Our Solution
- Waste elimination, cost transparency & operational alignment directly linked to measurable P&L improvement.
- Workforce & Cost Challenges. People’s problems are usually process problems.
Manpower & Capability
- High manpower costs, overtime fatigue, and attrition.
- Dependency on key individuals and skill gaps.
Our Solution
- Process-driven execution, workload balancing through Time & Motion studies
- System-led operations that reduce manpower dependency.
Cash Flow & Operating Costs
- Cash stuck in inventory & delayed receivables.
- Rising energy, maintenance & supply chain costs.
Our Solution
- Lean cost structures
- Faster cash cycles
- Data-backed decisions driven by on-ground Gemba insights.
Execution Tools
Value Stream Mapping
Time & Motion Studies
Root Cause Analysis
Process Controls
ABC Analysis
Just-In-Time Inventory
Poka-Yoke
Kaizen
Why Choose Gemba Concepts?
We are a management consulting firm supporting businesses in increasing profitability by operations improvement. Manufacturers across India, the Middle East, and Southeast Asia choose Gemba Concepts to drive real operational transformation. We empower businesses by aligning Man, Machine, Material, and Method for sustainable growth.
- Proven Impact Across Industries
- Collaborative Approach
- End-To-End Support
- Sustainability
Proven Results in Chemical Home Appliance Packaging Retail FMCG Industry
Case Study
How a Chemical Manufacturer Achieved 25% Faster Lead Times & 30% WIP Reduction
The Challenge
- High Work In Progress (WIP)
- Long & Unpredictable Manufacturing Lead Time
- Low Reactor Utilization
- Recurring Bottleneck
- Reactive Maintenance Downtime
- Fragmented Production Planning
What We Changed
- Analyze: Spaghetti Diagram— Gemba— Time & Motion Study— Bottleneck— Product Family
- Design: Pull System— Drum-Buffer-Rope (DBR)— Bucket Filling— Single Batch Flow Reallocation
- Sustain: Kaizen— Routine Maintenance Planning
The Challenge
- High Work In Progress (WIP)
- Long & Unpredictable Manufacturing Lead Time
- Low Reactor Utilization
- Recurring Bottleneck
- Reactive Maintenance Downtime
- Fragmented Production Planning
Business Impact
- More predictability.
- Less firefighting.
- Stronger cash flow.
The Results
25%
30%
85%
25%
Lead Time Reduction
Higher Reactor Utilization
On-Time Delivery
Lower WIP
Case Study
How a Home Appliances Manufacturer Improved Productivity by 50% & Reduced Lead Time by 90%
The Challenge
- Inefficient shopfloor layout
- High manual handling and excess movement
- Non-standardized post-molding activities
- Low manpower productivity
- Lack of standard processes
- Dependency on people instead of systems
What We Changed
- Analyze: Entire Process Flow Mapping — Gemba Walks — Time & Motion Study — Bottleneck Identification — Material Flow Analysis
- Design: Lean Layout — Single Piece Flow — Line Balancing — Multi-Manning — Packing Process Standardization
- Sustain: SOP Preparation — Skill Matrix — Team Training — Kaizen
The Challenge
- Inefficient shopfloor layout
- High manual handling and excess movement
- Non-standardized post-molding activities
- Low manpower productivity
- Lack of standard processes
- Dependency on people instead of systems
Business Impact
- Lower operating costs.
- Higher throughput with the same manpower.
- More stable and predictable operations.
- Reduced dependency on individuals.
The Results
20%
50%
90%
Manpower Cost Reduction
Productivity Improvement
Reduction in Lead Time
Case Study
How a Packaging Manufacturer Reduced Changeover Time by 30% & Improved Per-Shift Output by 20%
The Challenge
- Long and inefficient printing job changeovers
- High material wastage impacting profitability
- Low per-shift productivity in slitting & lamination
- Presence of Non-Value-Adding (NVA) activities
- Lack of standardized shopfloor practices
- Limited visibility of performance KPIs
What We Changed
- Analyze: As-is Process Mapping — Gap Analysis — Time & Motion Study — NVA Identification — Gemba Walks
- Design: SMED Implementation — 5S — Production Planning Optimization — Bottleneck Removal — Reuse of Rejected Materials for Job Setting
- Sustain: OPL & Team Training — Rewards & Recognition (R&R) Scheme — KPI Dashboards — Defined KRAs & Structured Handover
The Challenge
- Long and inefficient printing job changeovers
- High material wastage impacting profitability
- Low per-shift productivity in slitting & lamination
- Presence of Non-Value-Adding (NVA) activities
- Lack of standardized shopfloor practices
- Limited visibility of performance KPIs
Business Impact
- Faster changeovers and improved asset utilization.
- Reduced wastage and direct cost savings.
- Higher per-shift productivity.
- More disciplined and standardized shopfloor operations.
- Stronger process ownership and sustainability.
The Results
85 Lakhs
Savings from Wastage Reduction
Savings from Wastage Reduction
30%
20%
Reduction in Printing Job Changeover Time
Improvement in Lamination & Slitting Output per Shift
Case Study
How a Footwear Ecommerce Distribution Centre Cut Manpower by 22% While Increasing Orders per Person by 24%
The Challenge
- High product touchpoints across fulfilment stages
- Low orders processed per person
- Inefficient material movement within the warehouse
- Inventory imbalance and capacity constraints
- Process bottlenecks impacting order flow
- Lack of standardized layout and manpower structure
What We Changed
- Analyze: Spaghetti — Time/Motion — Inventory/Capacity — Bottlenecks — Line Balancing
- Design: In/out flow optimization — Lean layout — Conveyors — Manpower planning — POC validation
- Sustain: Infra build — Poka Yoke — WMS inventory — Standardized lean workflows
The Challenge
- High product touchpoints across fulfilment stages
- Low orders processed per person
- Inefficient material movement within the warehouse
- Inventory imbalance and capacity constraints
- Process bottlenecks impacting order flow
- Lack of standardized layout and manpower structure
Business Impact
- Higher operational efficiency at scale.
- Reduced dependency on manpower.
- Faster order fulfilment with fewer errors.
- Improved inventory visibility and control.
- Lean, scalable ecommerce distribution setup.
The Results
Inventory Mapping and Optimization through WMS
Lean Layout Design
22%
35%
20%
24%
Manpower Reduction
Improvement in Throughput Time
Improvement in Orders per Person
Reduction in Repacking Cost
Case Study
How This FMCG Manufacturer Cut PM Inventory Costs by 60% and Raised Productivity by 22%—Without Expansion
The Challenge
- High Packaging Material (PM) Inventory Holding Cost
- Low Manpower Productivity
- Finished Goods (FG) Shortfall due to Ineffective Production Planning
- Lack of Process Standardization
- Inefficient Layout & Excess Material Movement
- Manual Logbooks & Limited Visibility
What We Changed
Lean-driven FMCG Transformation using:
ABC Analysis, Just-In-Time (JIT), Line Balancing, Kanban, SMED, 5S, Kaizen, Bottleneck Analysis, Time & Motion Study, and Digitized Process Controls.
The Challenge
- High Packaging Material (PM) Inventory Holding Cost
- Low Manpower Productivity
- Finished Goods (FG) Shortfall due to Ineffective Production Planning
- Lack of Process Standardization
- Inefficient Layout & Excess Material Movement
- Manual Logbooks & Limited Visibility
Business Impact
- Lower working capital locked in inventory.
- Higher shop-floor productivity.
- Improved planning accuracy and dispatch reliability.
- Scalable operations through optimized layout design.
The Results
Optimized Layout
Enabled Installation of Additional Production Lines
22%
60%
99.5%
Productivity Improvement
PM Inventory Cost Reduction
On-Time In-Full (OTIF) Performance
Our Clients
Track Records
1M+
Man Hours of Consulting
500+
Clientele
30+
Over 30 States, 5 Countries and 2 Continents
Why They Chose Us — & What Followed
Director
“Gemba Concepts’ consultants work directly on the shop floor, which allows them to gain a deep understanding of our processes, challenges and opportunities.This hands-on approach has resulted in practical and tailored solutions that have reduced wastage, optimized processes, and increased overall equipment effectiveness (OEE).”
Executive Director
"Gemba Concepts demonstrated exceptional expertise in reducing operational bottlenecks, optimizing stock movement, and implementing data-driven inventory management."
CEO
“Throughout the project, they demonstrated exceptional expertise in implementing lean methodologies, reducing inefficiencies, streamlining production practices, and deploying technology-driven solutions for inventory control. Their contributions enabled us to improve service levels, optimize costs, and ensure seamless daily operations, while fostering a culture of continuous improvement.”
CEO
“The expertise and professionalism of the Gemba Concepts team have resulted in substantial cost savings. Their automation strategies have optimized our workflow and helped us to reduce waste & build a robust production management system.This focus on reducing waste has not only lowered costs but has also supported our commitment to sustainable business practice”
COO
“Gemba Concepts demonstrated exceptional expertise in implementing lean methodologies, reducing operational inefficiencies, streamlining warehouse management practices, and deploying technology solutions for maintenance tracking and inventory control.”
Director
“Their dedicated team efforts and innovative solutions backed by thorough data analysis helped us deliver our operational targets.”
Joint Managing Director
“Over the past few years, they have made significant contributions to our company’s growth and success by formulating KPIs and driving overall process improvement initiatives. They played a pivotal role in our OTIF project, which focused on improving our delivery performance and customer satisfaction.”
Managing Director
“Over the past few years, they have made significant contributions to our company’s growth and success by formulating KPIs and driving overall process improvement initiatives. They played a pivotal role in our OTIF project, which focused on improving our delivery performance and customer satisfaction.”
Managing Director
“We have seen significant improvement in our distribution centre with the redesign of the operations and changes in the information system, supported by Gemba Concepts during the development of the warehouse management system.”
Senior Vice President
“Gemba Concepts delivered professional and impactful services that significantly enhanced our ground-level processes and helped us identify actionable opportunities for improvement.Thanks to their involvement, we were able to streamline workflows, reduce waste, and enhance employee involvement in problem-solving.”
Managing Director
“Their hands-on approach and commitment to achieving measurable results have made a significant impact on our operational efficiency.”
Director
“Gemba Concepts demonstrated a deep understanding on lean manufacturing principles and had applied them to drive improvements in our operational efficiency and productivity.”
Director
“Their outstanding performance during this phase exceeded our expectations, leading us to extend their project for an additional four months to address other critical areas.”
Managing Director
“Gemba Concepts played a very significant role in not only improving the productivity of our company, but also the production team and our resources.They helped us implement OEE, improve quality, and define KPIs for strategic decision-making, leading to increased productivity and better performance.”
Managing Director
“The Gemba Concepts Private Limited Team demonstrated a profound and intrinsic understanding of our unique operational challenges, and their proposed solutions were not only pragmatic and effectively implemented but also strategically aligned with our long-term objectives for quality and efficiency. The tangible improvements we have observed are a direct testament to their expertise and professional diligence.”
Director-Operations
“Gemba Concepts Pvt. Ltd. consistently exceeded our expectations, showcasing their expertise in data management and visualization, order fulfillment (OTIF), inventory management and operations review systems. Their professionalism, analytical approach, and strong commitment make them a valuable partner for any organization aiming to elevate operational and supply chain excellence.”
CEO
“Gemba Concepts Pvt. Ltd. has demonstrated exceptional capability and professionalism, consistently delivering high-impact results in Human Productivity Improvement and Inventory Carrying Cost Optimization. Their data-driven approach, strong cross-functional coordination, and deep commitment to operational excellence make them an asset to any organization.”
“Gemba Concepts Pvt. Ltd. approached each improvement area with a structured methodology and ensured alignment with our organizational goals. Throughout the project, their team demonstrated strong domain knowledge, professionalism and adaptability, ensuring smooth execution and long-term value creation.”
Director
“Throughout the engagement, Gemba Concepts demonstrated an expertise in implementing Lean methodologies for addressing operational inefficiencies. Their professionalism, analytical approach, and commitment to continuous improvement were found satisfactory in every stage of the project.”
CEO
“Over the course of our four-month collaboration, the Gemba team consistently demonstrated professionalism, technical depth, and a results-oriented mindset. Their analytical thinking, methodical execution, and commitment to continuous improvement reflect a culture of excellence that aligns strongly with our own values.”
Managing Director
“The Gemba team consistently exhibited exceptional professionalism, deep technical expertise and a steadfast results-orientation. We wholeheartedly recommend Gemba Concepts Private Limited to any company seeking reliable, innovative, and results-driven solutions.”
See What’s Possible for Your Business
Consulting Services
Our Consulting Services
Business Process Reengineering
We rethink how your business operates to cut inefficiencies and produce tangible outcomes. We assist you in achieving quantifiable increases in productivity and cost control by utilizing technology and coordinating processes with strategy.
Digital Transformation & Automation
Too many businesses are hindered by manual labor, which slows down operations. We use digital tools and automation to improve your operations and reduce overhead by up to 50%.
Process Optimisation
Through precise KPI analysis and process mapping, we identify the bottlenecks impeding your operations. We fix them to increase OEE, improve inventory decisions, and increase productivity by up to 40%.
Plant Layout Design
Poor layouts waste space and cause manufacturing production to lag. We create optimized plant configurations that double output without additional shifts and increase efficiency by up to 25%.
Supply Chain Management
Every day, we witness supply chains collapsing due to delays and excess expenses. We design agile networks that double overall efficiency, reduce material touches by 41%, and speed deliveries by 30-45%.
Warehouse Management System (WMS)
We observe warehouses dealing with stock errors and slow dispatches that negatively impact their bottom line. We use cloud WMS to increase productivity by 50%, reduce dispatch times by 60% and lock in 99.9% accuracy.
Quality Management System (QMS)
We know defects and compliance issues erode profits and trust in manufacturing. We roll out ISO-ready QMS to slash defects by 70%, cut returns 25% and increase output per employee by 24%.
Manufacturing Consulting
Manufacturing lines are slowed down by imbalances in Man, Machine, Material & Method. We use 4M analysis and lean principles to increase throughput by over 40%, reduce changeovers by 30% and increase OEE by 25%.
Purchase, Vendor & Inventory Management
Stock imbalances and procurement delays reduce your profit margins. We use integrated analytics to strengthen vendor relationships and inventory. As a result, capacity can be obtained without any extra capital due to 40% faster cycles and 35% lower costs.
HR Consulting
We rethink your HR strategy using digital tools and analytics to reduce attrition by 30% and save up to ₹1.67 Cr a year.
Get in Touch
Change Starts With a Conversation
Schedule Meeting Today
Fill out the form, and let’s talk about how we can support your business.
Schedule Free Consultation
By submitting this form you agree to our Privacy Policy. Optimum may contact you via email or phone for scheduling or marketing purposes.
500+ Trusted Clients
Global Presence
- Continents
- Countries
- States
- Man Hours