Real Factories. Real Results. Real Profits.
See how we've helped 50+ SME manufacturers recover millions in hidden profits and achieve world-class operational excellence.
Company
Abhinandan Creations Pvt. Ltd.
Industry
Apparel Manufacturing
Team Size
250+
Timeline
6 months
The Challenge
Struggling with inefficient production processes, high waste levels, and inconsistent quality. Losing market share to faster competitors.
Our Solution
Implemented comprehensive Lean Transformation program with focus on value stream mapping, waste elimination, and team capability building.
Transformation Results
Productivity
Before: 100%
After: 165%
Lead Time
Before: 30 days
After: 18 days
Defect Rate
Before: 8%
After: 1.2%
Annual Savings
Before: Baseline
After: ₹3.2 Cr
Key Achievements
"Bringing The Idea Smith on board has been the best decision that we have taken for our organisation. They have given us a completely different viewpoint to look at the manufacturing process."Subash KubadiaManaging Director, Abhinandan Creations Pvt. Ltd.
Company
Topller Lifestyle Fashions Pvt. Ltd.
Industry
Fashion Accessories
Team Size
180+
Timeline
8 months
The Challenge
Rapid growth created operational chaos. Processes couldn't scale. Quality inconsistencies threatened reputation. Manual systems unable to handle increased order volume.
Our Solution
World-Class Manufacturing implementation combined with Digital Transformation. Integrated IoT sensors for real-time monitoring and automated quality control systems.
Transformation Results
Production Capacity
Before: 100 units/day
After: 185 units/day
Quality Score
Before: 92%
After: 99.2%
Inventory Costs
Before: ₹45L/month
After: ₹18L/month
ROI
Before: Baseline
After: ₹4.1 Cr
Key Achievements
"After seeing the success of other organisations, we wanted to use Lean methodologies to transform our company's internal processes and culture. The Idea Smith provided a hands-on, simple and methodical approach to the transformation process."Kapil GuptaManaging Director, Topller Lifestyle Fashions Pvt. Ltd.
Company
Best Marine Pvt. Ltd.
Industry
Marine Products
Team Size
120+
Timeline
7 months
The Challenge
Operating at capacity but couldn't meet growing demand. Expansion plans on hold due to operational inefficiencies. Needed to double output without massive capital investment.
Our Solution
Smart Factory implementation with focus on OEE improvement, predictive maintenance, and process optimization. Installed real-time monitoring and automated scheduling systems.
Transformation Results
OEE
Before: 62%
After: 89%
Machine Downtime
Before: 18%
After: 4%
Output per Worker
Before: 100%
After: 172%
Profit Margin
Before: 12%
After: 23%
Key Achievements
"The Continuous Improvement journey under the guidance of The Idea Smith is helping our Manufacturing Unit improve daily. We are now looking to accelerate our growth plans and soon undertake capacity expansion to double our output."Mohammed AminManaging Director, Best Marine Pvt. Ltd.
Ready to Write Your Success Story?
These results aren't outliers—they're what happens when you apply proven methodologies to SME manufacturing. Let's discuss how we can transform your factory.