| Symptom | Business Impact |
|---|---|
| Orders sit in queues for days | Lengthy cash cycle |
| Duplicate data entry across teams | Error-prone transactions |
| Senior managers approve minor spend | Bottlenecks in decision flow |
| Frequent firefighting on dispatch day | Higher overtime & freight cost |
| Phase | Tools Used | Outcomes |
|---|---|---|
| Map & Measure | Value-stream mapping, spaghetti charts | Baseline lead time, non-value-add % |
| Redesign | Lean waste lens, digital workflow mock-ups | Future-state map with 30-50 % LT reduction |
| Pilot | Kanban boards, quick-response QC | Live test on one family with wins in 4 weeks |
| Scale | SOP drafting, desk audits, job instruction | Roll-out factory-wide without stopping production |
| Lock-in | Dashboards, layered audits, coaching | Gains sustained through visuals & routines |
| Metric | Before | Target (12 weeks) |
|---|---|---|
| Order lead time | 18 days | ≤ 10 days |
| On-time delivery | 78 % | ≥ 95 % |
| Cost per unit | — | − 15 % |
| Working capital | — | + ₹25 lakh released |
A Pune automotive supplier eliminated three approval loops and automated dispatch paperwork. Cycle time fell 38 %, freeing ₹34 lakh in WIP and cutting late-delivery penalties by 80 %.