Make Your Existing Capacity Deliver Higher OEE & Throughput

Every minute of downtime reduces your production potential. Our OEE consulting targets the bottlenecks, changeover losses, and shop-floor variability that quietly cap output, so you increase throughput without additional capital investment.

500+ Clients Served12+ Years40+ Sectors1M+ Man Hours

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Why Your Plant Isn't Producing More?

Hidden Bottlenecks Are Stealing Your Throughput

Most plants lose 20-40% of their capacity through operational losses that have quietly become part of everyday work.

Manufacturing throughput improvement visual
OEE and changeover optimization

Issue 1

Production targets keep getting missed

Bottlenecks and flow constraints limit output, even when teams are working hard.

How Gemba helps

We identify and remove the constraints limiting flow. Result: 53.9% throughput improvement in cable manufacturing.

Issue 2

Changeovers take too long.

Every minute spent on setup is production time lost forever.

How Gemba helps

Using SMED, we reduce setup time and improve machine availability. Result: Up to 47% reduction in changeover time.

Issue 3

Microstoppages go unnoticed

Small stoppages rarely get recorded, but collectively they consume hours of production.

How Gemba helps

We find the recurring interruptions and remove their root causes. Result: 449 production minutes recovered per month.

Issue 4

Lines are not properly balanced

When one process slows down, the entire line slows with it

How Gemba helps

Line balancing and Yamazumi analysis recover hidden capacity. Result: 269% productivity improvement on a manual assembly operation.

THE GEMBA APPROACH

01

Assessment & diagnostics

A 2-4 day on-site study. We walk your floor, observe your processes, and find where time, output, and cost are quietly being lost.

02

Scope, deployment & commercials

Scope defined from your data, not a template. Commercials built on a clear ROI case, so the decision to proceed is grounded in numbers.

03

Current state mapping & baseline

Every process mapped in detail. A signed performance baseline established - the reference point against which every improvement is measured.

04

Proof of concept, implementation & on-site training

Solutions validated on the floor before full rollout. Implementation happens alongside your team. Training happens at the Gemba, in real conditions, under real pressure.

05

Sustenance & audit handover

Review systems and audit structures built into your team before we step back. We do not exit on a deadline. We exit when the results hold.

Results we delivered

Solar manufacturing throughput improvement

Solar Manufacturing 37% increase in finished goods output

  • From 1,404 to 1,923 modules per day
  • OEE improved from 38.4% to 53.7%
  • Line downtime reduced across major loss categories
  • TPM and autonomous maintenance implemented
  • Achieved within 6 months
Cable manufacturing throughput gains

Cable Manufacturing 53.9% throughput improvement

  • Achieved within 6 months
  • Rolling mill output increased by 35.3%
  • Conductor output improved by 25.8%
  • 18.1% overall productivity improvement
  • ₹25 Cr revenue impact delivered
Printing and packaging OEE improvements

Printing & Packaging 123% OEE improvement across operations

  • 36.6% reduction in material wastage
  • 47% reduction in changeover time
  • Real-time OEE visibility enabled
  • Live OEE dashboard deployed and handed over
Composite manufacturing throughput improvement

Composite Manufacturing 58% output improvement through debottlenecking

  • 25% OEE improvement across key production lines
  • 37% reduction in changeover time
  • Maintenance management system established
  • Live throughput tracking implemented across all lines

Trusted by

500+

Industrial Businesses Across 3 Continents

TCS
Godrej & Boyce
Ashok Leyland
Kajaria
Kenstar
Joyalukkas
Safari
Cello
Asian
TCS
Godrej & Boyce
Ashok Leyland
Kajaria
Kenstar
Joyalukkas
Safari
Cello
Asian
TCS
Godrej & Boyce
Ashok Leyland
Kajaria
Kenstar
Joyalukkas
Safari
Cello
Asian
TCS
Godrej & Boyce
Ashok Leyland
Kajaria
Kenstar
Joyalukkas
Safari
Cello
Asian
Rupa
Happilo
Veedol
Arvind
GIVA
Snitch
Bagmane
Pyramid
Shalco
Rupa
Happilo
Veedol
Arvind
GIVA
Snitch
Bagmane
Pyramid
Shalco
Rupa
Happilo
Veedol
Arvind
GIVA
Snitch
Bagmane
Pyramid
Shalco
Rupa
Happilo
Veedol
Arvind
GIVA
Snitch
Bagmane
Pyramid
Shalco
Testimonials

What Our Clients Say

Wires & Cables ManufacturingIndia

Their hands-on approach has resulted in practical and tailored solutions that have reduced wastage, optimized processes, and increased overall equipment effectiveness (OEE).

Jainam Deliwala

Director

Rolliflex Pvt Ltd

Jainam Deliwala
1/15

Industries We Serve

Experience Across Diverse Industries

We have supported manufacturers across these sectors.

Automotive & Auto Components
Pharmaceuticals & Life Sciences
FMCG & Consumer Goods
Engineering & Industrial Manufacturing
Chemicals & Process Industries
Printing & Packaging
Textile & Apparel
Solar & Renewable Energy
Automotive & Auto Components
Pharmaceuticals & Life Sciences
FMCG & Consumer Goods
Engineering & Industrial Manufacturing
Chemicals & Process Industries
Printing & Packaging
Textile & Apparel
Solar & Renewable Energy
Automotive & Auto Components
Pharmaceuticals & Life Sciences
FMCG & Consumer Goods
Engineering & Industrial Manufacturing
Chemicals & Process Industries
Printing & Packaging
Textile & Apparel
Solar & Renewable Energy
Automotive & Auto Components
Pharmaceuticals & Life Sciences
FMCG & Consumer Goods
Engineering & Industrial Manufacturing
Chemicals & Process Industries
Printing & Packaging
Textile & Apparel
Solar & Renewable Energy

Ready To Recover Lost Throughput?

Every day your plant operates below its true potential, valuable production and profit are left behind.

Schedule A Meeting Today

Schedule a Consultation

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