Up to 60%
Inventory Cost Reduction
Reduce excess inventory and release working capital.
Inventory Planning Consulting
Many manufacturers are overstocked and underprepared at the same time. Cash gets locked in slow-moving inventory while critical materials run short.
We help manufacturers build inventory norms that improve availability, reduce inventory costs and free up working capital.
India | Middle East | Africa
Talk to Our Experts Today
Results Section
What You Gain
Up to 90%
Shortage Reduction
Improve material availability for production and dispatch.
99.5%
OTIF Achievement
Deliver orders on time and in full.
Up to 35%
Inventory Carrying Cost Reduction
Lower storage, holding, and obsolescence costs.
Pain Point Section
Is Inventory Draining Your Working Capital?
Excess inventory consuming working capital
High stock levels increase carrying costs and reduce cash available for growth and operations.
Frequent stock shortages
Critical materials run out despite significant inventory investment across the business.
Inventory levels based on assumptions
Stocking decisions are often driven by experience and judgement rather than structured planning.
Lack of inventory segmentation
Fast-moving, slow-moving, and critical items are managed using the same replenishment logic.
Dead and obsolete inventory accumulation
Non-moving stock continues to occupy warehouse space and consume working capital.
Poor reorder point management
Safety stock and replenishment levels are not aligned to actual consumption and lead-time variability.
Inventory disconnected from demand
Procurement and stocking decisions often operate independently of production and sales requirements.
High inventory with low service levels
Organizations carry excess stock while still struggling to meet customer and production demand consistently.
Solution Section
Where We Help You Succeed
Inventory Analysis & Classification
Segment inventory using ABC, XYZ, and movement-based analysis to improve inventory control.
Inventory Norm Development
Establish scientifically calculated reorder points, safety stock levels, and replenishment quantities.
SKU Segmentation Strategy
Apply differentiated inventory policies based on demand patterns and business criticality.
Make-to-Stock & Make-to-Order Planning
Define inventory strategies that balance service levels and working capital requirements.
Slow-Moving & Excess Inventory Reduction
Identify and systematically reduce non-moving and surplus inventory.
Kanban & Pull Replenishment Systems
Implement structured replenishment systems driven by actual consumption.
Demand & Supply Alignment
Synchronize inventory planning with production schedules and customer demand.
Inventory Visibility & Performance Dashboards
Build monitoring systems that provide real-time visibility into stock levels, ageing, shortages, and inventory performance.
Convert Inventory Norms to Digital Control
Real-Time Inventory Intelligence
Our inventory intelligence platform tracks SKU by SKU, triggers replenishment based on real consumption and warns of the risk of aging or shortage before it becomes a problem. So inventory decisions are driven by data, not instinct.
See How It WorksInventory Cost
−60%
excess reduced
Shortages
−90%
reduction
OTIF
99.5%
achievement
Carrying Cost
−35%
savings
Our Approach
The Gemba Approach
A proven 5‑phase methodology delivered on your shop floor — not from a boardroom. Every phase is hands‑on, data‑backed, and measured against a signed baseline.
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.
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.
Current state mapping & baseline
Every process mapped in detail. A signed performance baseline established — the reference point against which every improvement is measured.
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.
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.
We don't exit on a deadline. We exit when the results hold.
Every engagement includes audit handover and built‑in review systems.
Case Studies Section
Featured Case Study
Real project outcomes across supply chain and inventory planning, with measurable cost reductions and sustained availability improvements.
Construction Industry
30% Procurement Lead Time Reduction
A construction company transformed a highly manual procurement process by implementing structured purchase requests, approval workflows, purchase orders, quotation management, and delivery tracking systems. Procurement lead times reduced by 30% while visibility improved across multiple project locations.
30% lead time reductionMulti-location visibilityStructured procurement workflows
Key Levers
- Structured purchase requests
- Approval workflows
- Purchase order management
- Delivery tracking systems
Electrical & Lighting Manufacturing
Vendor OTIF Improved from 48% to 64%
A leading electrical products manufacturer improved supplier reliability through vendor scorecards, demand visibility, centralized planning, and structured supplier performance reviews. Vendor OTIF improved significantly while order fill rates increased from 93.7% to 96.1%.
48% → 64% vendor OTIF93.7% → 96.1% fill rateStructured supplier reviews
Key Levers
- Vendor scorecards
- Demand visibility
- Centralized planning
- Structured supplier performance reviews
Frequently Asked Questions (FAQ's)
Common Questions, Clear Answers
Everything companies usually ask before starting an Inventory Planning & Norms engagement.
What are inventory norms?
Predefined stock limits such as minimum, maximum, reorder point, and safety stock.
How do inventory norms improve operations?
They ensure timely replenishment and reduce both shortages and excess stock.
Can inventory planning reduce working capital?
Yes. Optimized inventory levels reduce unnecessary stock holding.
Do you support ERP-based implementation?
Yes. We align ERP parameters with operational planning requirements.
How soon can improvements be seen?
Most results become visible within 60–90 days.
Contact
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a Conversation
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