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Other Case Studies

Godrej Electricals & Electronics

Most new projects could be delvered ahead of time and profitability improved more than
Rapid Projects Execution
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Walkaroo International

Within a year, new product output improved by 75% and availability at plant warehouse reached
Rapid Flow R&D
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Raychem RPG (P) Ltd

Raychem RPG (P) Ltd.

Profits and ROCE improved by more than
High Velocity Custom Manufacturing
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Skipper Pipes Limited

Manufacturers a range of CPVC pipes and fittings for hot and cold plumbing
Pull Manufacturing & Distribution
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Ashok Leyland – NPD

More than a year of implementation, the company was not only able to streamline its transition from BS4 to BS6 but they
Rapid Flow R&D
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Godrej Interio (Institutional Business)

Until recently the company was struggling to complete projects on time but within one year of TOC implementation, lead
Sales Productivity Enhancement
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Kirloskar Ferrous Industries Ltd (KFIL)

The company’s customer on-time delivery increased to 100% on daily basis and significantly increased SOB with key
High Velocity Custom Manufacturing
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Westside

Part of Trent Ltd, it is a leading brand in lifestyle and apparel
Solution for Retail
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Viveks

Leading consumer electronics and home appliances retail chain in
Solution for Retail
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Godrej Hershey’s

Manufactures and distributes food and
Pull Manufacturing & Distribution
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Khadims

A leading footwear
Pull Manufacturing & Distribution
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APL Apollo Tubes Limited (APL Apollo)

Leading manufacturers of branded steel
High Velocity Custom Manufacturing
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FBB

The fashion arm of Big Bazaar offering apparel for men, women and kids
Solution for Retail
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Asian Granito

Manufacturer of various kinds of tiles including vitrified tiles, ceramic tiles, wall tiles and agglomerated marble
Pull Manufacturing & Distribution
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TATA International

A global trading and distribution company
High Velocity Custom Manufacturing
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Century Plyboards India Ltd.

Manufactures, sells and exports plywood and
Sales Productivity Enhancement
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Sintex Industries Limited

Leader in plastic processing products like panel tanks, PVC doors
Pull Manufacturing & Distribution
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Pidilite

A market leader in adhesive, industrial and construction chemicals, and art material. Leading brands include Fevicol, M
Pull Manufacturing & Distribution
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Badve Engg

Manufacturer of two-wheeler frames, two-wheeler chassis, crossmember, four-wheeler chassis, three-wheeler chassis etc
High Velocity Custom Manufacturing
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SKF

A leader in providing automotive and industrial engineered solutions through its five technology-centric platforms:
Pull Manufacturing & Distribution
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Volvo Eicher

Joint venture betwenn Volvo Group and Eicher Motors, for manufacturing commercial vehicles in
Solution for Spares & Services
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Royal Enfield

A global leader in mid-sized motorcycle segment
Solution for Spares & Services
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Tata Autocomp Systems Ltd

Part of Tata Motors, distributes commercial vehicles and spare parts in South
Pull Manufacturing & Distribution
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Shriram Pistons

Largest manufacturer and exporter of pistons and rings from India
High Velocity Custom Manufacturing
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Filtrum Polymers Pvt. Ltd.

In the first six months of implementation itself, the firm released more than 60% additional capacity and improved
High Velocity Custom Manufacturing
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Raychem RPG

A joint venture between TE connectivity and RPG Group, it is market leader in innovative energy & hydrocarbon solutions
High Velocity Custom Manufacturing
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PARI

Develops and provides automation solutions using world class robotic products and technologies
Rapid Flow R&D
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Action Construction Equipment Limited - ACE Cranes

Leading material handling, construction equipment manufacturing company
High Velocity Custom Manufacturing
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MSP Steel

An integrated steel plant with a wide range of products including bars, pellets, sponge iron, ferro alloys, billets,
High Velocity Custom Manufacturing
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Greaves Cotton

Manufacturers of diesel/petrol engines, farm equipment and
High Velocity Custom Manufacturing
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Yellow Diamond (Prataap Snacks)

Prataap Snacks, under the brand name Yellow Diamond, is one of the leading manufacturers and distributors of chips and
Pull Manufacturing & Distribution
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Sales Productivity Enhancement
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L&T – Heavy Engineering

Makes engineered to-order equipment for process industries such as fertilizer, chemical, refinery,
High Velocity Custom Manufacturing
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Jindal Stainless Steelway

Jindal Stainless Steelway Limited processes and distributes cut-to-size polished stainless steel sheets, coils and
Pull Manufacturing & Distribution
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Shanthi Gears

Makes a wide range of industrial power transmission products including gears and gear
High Velocity Custom Manufacturing
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Lenskart

One of India's fastest growing eyewear
Pull Manufacturing & Distribution
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Linc pens

A well known writing instrument manufacturer with a national and international
Sales Productivity Enhancement
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Kelloggs

World's leading cereal company; second largest producer of crackers and savory
Pull Manufacturing & Distribution
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Polycab

Manufactures and sells cables, wires and electrical
High Velocity Custom Manufacturing
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Dr. Reddy’s Laboratories

Dr. Reddy's Laboratories manufactures and markets a wide range of pharmaceuticals in India and overseas. The company
Rapid Flow R&D
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Shalimar Paints

One of India's oldest paint manufacturing
Pull Manufacturing & Distribution
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Salasar Techno Engg.

An Indian infrastructure company offering customers a one-stop shop for engineering, designing, procurement,
Rapid Projects Execution
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Daawat

Leading brand in India offering premium and finest grains of basmati
Sales Productivity Enhancement
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Godrej AV

Leading audio visual solutions provider for applications such as boardrooms, conference rooms, auditoriums, training
Rapid Projects Execution
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Kurl-on

India's leading brand of mattresses, furniture and furnishing
Pull Manufacturing & Distribution
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Skipper EPC

This division undertakes transmission line projects connecting power transmission
High Velocity Custom Manufacturing
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Godrej security solutions PSS

The company deals with procuring and installing custom security solutions for
High Velocity Custom Manufacturing
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Rapid Projects Execution
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TATA Steel

It is the world’s second-most geographically diversified steel
High Velocity Custom Manufacturing
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Godrej Interiors

A business unit of Godrej Interio, it designs and executes interiors of commercial
Rapid Projects Execution
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Sterlite Tech

Global technology leader that designs, builds and manages smarter digital
Rapid Projects Execution
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Dollar Industries

A leading producer of fashion innerwear, loungewear, gym wear, sleepwear and track
Sales Productivity Enhancement
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Blackberrys

A premium brand in men's apparel and
Pull Manufacturing & Distribution
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Shakti Pumps

India’s leading manufacturer of energy efficient submersible
Pull Manufacturing & Distribution
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Godrej Megasari

The company’s largest modern trade partner dramatically reduced its inventory (41%) while improving availability to a
Pull Manufacturing & Distribution
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Kirloskar Agri

Manufacturers of diesel engines and agricultural pump
Pull Manufacturing & Distribution
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Bajaj Electricals Limited (CP)

With the objective of increasing sales by addressing the sales lost due to unavailability, the company adopted TOC
Pull Manufacturing & Distribution
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VIP Industries Ltd

Not only did the stock availability increase to more than 90%, the company also saw its own stores grow by
High Velocity Custom Manufacturing
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Ajanta Pharma

A specialty pharmaceutical company engaged in development, manufacturing and marketing of quality finished drugs in
High Velocity Custom Manufacturing
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Sun Pharma

Manufacutres and markets > 300 APIs, to customers in over 60 countries across the
High Velocity Custom Manufacturing
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Godrej Interio-NPI

Until recently the company was struggling to complete projects on time but within one year of TOC implementation,
Rapid Flow R&D
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Strides

A specialty pharmaceutical company engaged in development, manufacturing of generic pharma
High Velocity Custom Manufacturing
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Vaibhav Global Limited

Manufacturer and exporter of fashion jewellery and lifestyle
High Velocity Custom Manufacturing
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Lupin

It is one of the largest generic pharmaceutical companies by revenue
Rapid Flow R&D
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Jindal Stainless Limited

Production transitioned from MTO to “pull” replenishment-based MTA for nearly 1,000 SKUs (~70% of total
High Velocity Custom Manufacturing
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Trident Group

Adopting TOC principles, the company erected a spinning plant of 30,000 spindles, in a record time of nine
Rapid Projects Execution
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Raymond

Manufacturer of suiting
High Velocity Custom Manufacturing
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Liberty Shoes Ltd

The company has achieved over 97% availability in its central warehouse, probably amongst the best in the fashion
Pull Manufacturing & Distribution
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Tata Motors-Spare Parts & Services Division (Commercial Vehicles)

After implementation, the daily availability of spare parts increased from 75% to 93%, & inventory reduced from 67days
Pull Manufacturing & Distribution
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Fleetguard Filters Pvt. Ltd. (NPD)

In addition to reduction in stress levels of people, productivity improved three times and iterations reduced by more
Rapid Flow R&D
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Trident

Adopting TOC principles, the company erected a spinning plant of 30,000 spindles, in a record time of nine
High Velocity Custom Manufacturing
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Fleetguard Filters

The firm built a new plant in a rain ravaged location in eight months (industry standard lead-time of over 12-14
Rapid Projects Execution
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Tata Metaliks

The blast furnace shut down was completed well within budget (87%) and in a record of 23
Rapid Projects Execution
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Tata Bluescope Steel Limited

Lead time of projects reduced by 25%; manufacturing output increased by 15%; engineering resources output increased by
Rapid Projects Execution
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Godrej-electricals-and-electronics

Godrej PIRE

Most new projects could be delivered ahead of time and profitability improved more than
Rapid Projects Execution
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Bajaj Electricals Engineering And Projects Division

With the new paradigm of synchronized supply and execution management, the company now delivers most projects 3-4
Rapid Projects Execution
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KEI Industries Ltd

KEI Industries Ltd., used flow principles of TOC to seamlessly align purchase/material delivery to site requirements
Rapid Projects Execution
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A Major Vertically Integrated Linen Exporter

After adopting TOC "pull" manufacturing, this company was able to improve OTD to 95% from earlier
High Velocity Custom Manufacturing
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Raymond Zambaiti Ltd

Within eight months of implementing TOC, production lead-time reduced by 25%; OTIF improved to
Sales Productivity Enhancement
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Pratibha Syntex Ltd

This integrated textile company saw its OTIF increase to 90% and profits go up by 55% after adopting
High Velocity Custom Manufacturing
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Godrej-Interio

Godrej Interio

In addition to crashing lead-time of regular orders, the company now also offers an assured seven days
High Velocity Custom Manufacturing
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Liberty Retail Revolution Ltd

Within a year, the company improved the store inventory cover from 10 months to five months, while increasing sales by
Solution for Retail
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Landmark

The company put in place robust mechanisms to effectively manage its portfolio and its product mix in
Solution for Retail
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JK Files And Tools

Using TOC solutions, JK tools increased output by 30% from existing capacity within six months of
High Velocity Custom Manufacturing
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Godrej-Interio

Godrej Interio- Service And Spares

Service levels improved (complaints reduced by 55%) by process improvement & without increasing the fixed
Solution for Spares & Services
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Godrej-Interio

Godrej Interio-Home Kitchens

With implementation of TOC operations solutions, the ex-factory OTIF performance has gone up from around 50% to
Pull Manufacturing & Distribution
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Parag Milk Foods Ltd.

They experienced a 56% increase in average sales per day and 200% jump in outlets billed after adopting
Sales Productivity Enhancement
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Top1 Lubricants, Indonesia

This Indonesian company reduced its inventory from seven months to two months while improving availability to near 100%
Pull Manufacturing & Distribution
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Tata Radiators

The implementation of the TOC flow Management solution in NPD has doubled the output rate of new products
Pull Manufacturing & Distribution
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Mahindra First Choice (Spares And Services)

Without any offering schemes or discounts this young company increased average daily sales by
Pull Manufacturing & Distribution
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Mahindra First Choice Services

Within a year, turnaround time reduced to 58% and the revenue generated per work hour increased by
Pull Manufacturing & Distribution
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Lucas Indian Service Ltd.

Same-day order fill rate of the firm improved from 50% to 80%; distributors’ sales grew by
Pull Manufacturing & Distribution
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JK Fenner (India) Ltd

JK Fenner has transformed its operations by providing higher availability (>90%) of its products as well as faster and
High Velocity Custom Manufacturing
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Fleetguard Filters Pvt Ltd

After a company-wide implementation of TOC, the company enjoyed a CAGR of 25% in the last 10
High Velocity Custom Manufacturing
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Ashok Leyland- Spares Parts Division

Post implementing the TOC distribution model, the company’s spares business continued to grow at over 25%
Pull Manufacturing & Distribution
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International Tractors Limited

After implementing TOC, the company ensures near-perfect availability of components and tractors while reducing
High Velocity Custom Manufacturing
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Lakshmi machin works

LMW Machine Tool Division (MTD)-New Product Development

After implementation of TOC, lead-times for NPD crashed and contribution of new products to sales increased three times
Rapid Flow R&D
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Hercules Hoists Limited

Production was streamlined by implementing Theory of Constraints based on “pull” manufacturing
High Velocity Custom Manufacturing
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Godrej Tooling

On-time delivery of ETO projects improved to 85%; overall lead time
High Velocity Custom Manufacturing
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Filtrum Tools

The company reduced overall lead-time by 25%, and improved on-time delivery performance to about
High Velocity Custom Manufacturing
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Godrej Storage Solutions

A new supply chain segment was created for supplying standard products with three-day guaranteed
High Velocity Custom Manufacturing
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Bajaj Luminaires Division

The on time in full delivery performance of the firm improved to 85% (industry standard is
High Velocity Custom Manufacturing
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Godrej Securities Solutions

Within two years of implementation, profits tripled, and then quadrupled in the third
High Velocity Custom Manufacturing
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Kirloskar Oil Engines Ltd (Spares And Services)

After implementation, availability of spares at service points increased to 96% while overall inventory fell by
Solution for Spares & Services
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Godrej Material Handling

Within a few months of implementation, manufacturing lead-times crashed to
High Velocity Custom Manufacturing
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Lakshmi Machine Works Ltd. (Machine Tool Division)

After implementation of TOC, lead-times for NPD crashed and contribution of new products to sales increased three times
High Velocity Custom Manufacturing
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Kirloskar Oil Engines Ltd. (KOEL)

After moving from forecast-based to consumption-based operations, the company now offers guaranteed deliveries in one
Pull Manufacturing & Distribution
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