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OEE & Throughput Improvement
OEE & Throughput Improvement Consulting
Your factory has more capacity than you think. Low OEE, unplanned downtime, and bottlenecks are silently reducing your production capacity and profits. Our experts help you improve throughput using Lean Manufacturing and TPM — without investing in new machines.
500+
Clients Served
1M+
Consulting Hours
40+
Sectors
5
Countries
Full-time on-site consultants
Shop floor execution, not just advisory
Results embedded into daily operations
Serving India, Middle East, and SE Asia
What You Get
What You Get
02
Eliminate Minor Stops & Speed Losses
03
Optimize Production Cycle Time
04
Increase Factory Throughput
What We Solve
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 become normalized.
01
Production Bottlenecks Restricting Output
One bottleneck station limits the performance of the entire production line, often remaining hidden until detailed analysis is conducted.
We identify and eliminate the constraints limiting production flow through bottleneck analysis and throughput optimization.
Result: 53.9% throughput improvement achieved in cable manufacturing.
02
Unbalanced Workflows and Line Inefficiencies
Some stations remain idle while work accumulates at others, creating uneven flow and reducing overall line productivity.
We use line balancing and Yamazumi analysis to distribute workloads effectively and improve production flow.
Result: 269% productivity improvement achieved in a manual assembly operation.
03
Excessive Work-In-Progress (WIP)
High WIP consumes valuable floor space, working capital, and operator attention while masking underlying flow issues.
We optimize production flow, remove constraints, and improve process synchronization to reduce unnecessary inventory buildup.
Result: Improved flow visibility and faster movement of materials across operations.
04
Material Movement Delays
Poor facility layouts and inefficient material flow increase travel distances, handling effort, and production delays.
We redesign material flow and optimize shop-floor layouts to reduce non-value-added movement.
Result: 40% reduction in material movement waste achieved in FMCG manufacturing.
05
Inconsistent Cycle Times
Without standardized work, the same task is performed differently across operators and shifts, creating variation in output.
We establish standardized work methods, cycle time controls, and operating standards to improve consistency.
Result: Improved process stability and predictable production performance.
06
Downtime Losses Affecting Productivity
Unplanned breakdowns, microstoppages, slow changeovers, and maintenance delays reduce available production time.
We implement TPM, OEE tracking, downtime analysis, and changeover improvement initiatives to recover lost capacity.
Result: 40% improvement in throughput time across manufacturing operations.
Proven Results
Real Transformations. Measurable Numbers.
These are implemented outcomes from manufacturing plants, not projection models.
Solar Manufacturing
37% increase in finished goods output
- Output Increase
- 37%
- Final OEE
- 53.7%
- Delivery Horizon
- 6 Mo
OEE improved from 38.4% to 53.7% within 6 months.
Cable Manufacturing
53.9% throughput improvement
- Throughput Gain
- 53.9%
- Productivity Lift
- 18.1%
- Revenue Impact
- INR 25 Cr
Rolling mill and conductor output improved with a strong revenue impact.
Printing & Packaging
40% improvement in throughput time
- Throughput Time
- 40%
- Changeover Reduction
- 47%
- Wastage Reduction
- 36.6%
Changeover and wastage reductions were backed by live OEE visibility.
Composite Manufacturing
58% output improvement through debottlenecking
- Output Improvement
- 58%
- OEE Improvement
- 25%
- Setup Time Reduction
- 37%
Maintenance and tracking systems stabilized line performance.
Our Method
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.
Industries We Serve
Experience Across Diverse Industries
We have supported manufacturers across:
AutomotiveAuto ComponentsPharmaceuticalsLife SciencesFMCGConsumer GoodsEngineeringIndustrial ManufacturingChemicalsProcess IndustriesPrintingPackagingTextileApparelSolarRenewable Energy
Client Voices
What operators say after we leave.
Trusted by Industry
500+
Industrial Businesses Across 3 Continents
Frequently asked questions
Let's Talk
Ready To Recover Lost Throughput?
Book a free consultation. We will review your current constraints and outline where your recoverable capacity is sitting.
No commitment. A focused 30-minute conversation.
Speak directly with a senior operations consultant.
Specific inputs based on your plant constraints.
Response within 24 hours.