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Leadership team and consultants working at a value stream map

Capabilities

Six practices, installed as one system

Each practice stands on its own. Together they share one set of data, one standard work and one team, which is why the gains hold.

Aerial view of a new manufacturing plant nearing completion

01

Greenfield plants

From bare land to a running line, with flow, people and data designed in before the concrete is poured.

What we do

  • Feasibility, site selection and capacity model
  • Flow-based layout and line balancing
  • Machine specification, vendor trials and commissioning
  • Utilities, approvals and ramp-up to target

What you keep

  • Detailed project report and capex plan
  • Layout drawings and material-flow study
  • Commissioning and validation records
  • Ramp-up curve with weekly targets

0 → 1land to first article

Leadership team and consultants working at a value stream map

02

Operations & lean

Value stream mapping, line balancing and standard work that turn days of waiting into hours of flow.

What we do

  • Value stream mapping, current and future state
  • Time study, SMV and operation bulletins
  • Line balancing, cells and WIP limits
  • Cost per minute and costing per piece

What you keep

  • VSM with loss quantified in rupees
  • Operation bulletins for every product
  • Standard work and visual factory
  • Daily tiered review boards

+18%throughput in 11 weeks

Trainer coaching women operators at a training line

03

People & HRMS

Organisation design, hiring, skills and pay that make a new standard the way the shift actually works.

What we do

  • Organisation design and manpower norming
  • Hiring funnels and training academies
  • Skills matrix, certification and career paths
  • Attendance, shift and payroll integration

What you keep

  • Skills matrix on every line
  • Picture and video SOP library
  • Incentive design linked to skill
  • HRMS with biometric attendance

1record for every operator

Quality inspector checking stitching under a magnifier lamp

04

Quality, chemistry & ESG

Quality built in at source, chemistry held inside its window, and compliance that survives any audit.

What we do

  • Quality gates, SPC, MSA and 8D root cause
  • Adhesives, compounds and finishing chemistry
  • Buyer, social and RSL / chemical compliance
  • Energy, carbon (Scope 1–3), HIGG FEM, ZDHC, ISO 14001 / 45001

What you keep

  • Quality plan and gate checklists
  • Process windows for every recipe
  • Audit-readiness tracker
  • Energy and carbon baseline

3scopes, measured not estimated

Technician checking a motor with a vibration analyser

05

Maintenance & reliability

Total productive maintenance that makes the machine available because the operator owns it.

What we do

  • Autonomous and planned maintenance
  • OEE loss trees down to the six big losses
  • SMED for moulds, lasts and dies
  • Spares strategy and condition monitoring

What you keep

  • PM calendar and checklists per machine
  • OEE dashboard by line
  • Changeover standards
  • Critical spares list

85%world-class OEE, held

Engineer reviewing production dashboards in a control room

06

AI & digital

Bluro AI, our own manufacturing ERP, with models that run on the line rather than in a pilot deck.

What we do

  • Bluro AI ERP: orders to dispatch in one system
  • Vision inspection at line speed
  • Failure prediction on critical assets
  • Demand and delivery-date forecasting

What you keep

  • Live plant dashboards
  • Shop-floor data layer
  • Trained in-house super-users
  • Model performance review each month

11 wkpilot to production

Why one system

Quality defines the truth

What counts as a defect, measured the same way twice. Without it every model learns someone’s opinion.

Maintenance gives AI something to act on

A prediction with no planned-maintenance route behind it is just a notification.

People decide whether it survives

Skills, shifts and incentives turn a new standard into the way the shift actually runs.

ESG reads the same meter

Energy data that feeds the OEE model also feeds carbon accounting. Measured once, used twice.

Tell us what the plant is doing that it should not be.

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