Scope of Service
Daily
Operational Review & Tactical Huddles.
- Structured daily Zoom/Teams meetings with plant managers and department heads.
- Review of production targets, shift performance, and machine utilization.
- Real-time feedback on bottlenecks, safety issues, and corrective actions.
- Escalation protocols for unresolved issues.
- Daily action item tracking and accountability matrix
Live
KPI Monitoring & Performance Dashboards
- Real-time dashboards for OEE, scrap rate, cycle time, and downtime.
- Automated alerts for deviations in quality, safety, or productivity.
- Customizable views for department-specific metrics.
- Historical trend analysis and benchmarking.
- Integration with MES/ERP systems
Production
Line Diagnostics & Troubleshooting
- Remote analysis of machine logs and PLC data.
- Root cause identification for unplanned downtimes.
- Recommendations for parameter tuning and process stabilization.
- Support for sensor calibration and signal integrity.
- Workflow reconfiguration for throughput improvement
Quality
Assurance & Regulatory Compliance
- Review of inspection data, defect trends, and customer complaints.
- Guidance on ISO 9001, IATF 16949, and customer-specific standards.
- Support for CAPA (Corrective and Preventive Action), FMEA (Failure Mode and Effects Analysis), and internal audits.
- Digital traceability and documentation review.
- Supplier quality assurance and incoming inspection protocols,
Advanced
Process Optimization
- Deep-dive into moulding, and assembly processes.
- Simulation-based recommendations for cycle time and energy reduction.
- Support for lean manufacturing and Six Sigma initiatives.
- Bottleneck identification and process balancing.
- Optimization of material flow and layout design
Maintenance
Strategy & Reliability Engineering
- Preventive and predictive maintenance planning.
- Remote support for breakdown analysis and MTTR/MTBF tracking;
- Asset criticality ranking and spares optimization;
- Lubrication and vibration analysis advisory'
- Maintenance cost tracking and ROI evaluation
Inventory & Materials Management
- Monitoring of raw material levels, reorder points, and stock aging.
- ABC/XYZ classification and inventory turnover analysis.
- Vendor-managed inventory (VMI) and JIT implementation support.
- Obsolescence tracking and slow-moving stock alerts.
- Inventory reconciliation and audit support.
Procurement
& Supplier Performance
- Evaluation of supplier KPIs: OTIF, quality, cost, responsiveness.
- Strategic sourcing and negotiation support.
- Risk assessment of supply chain dependencies.
- Supplier scorecard development.
- Contract compliance and renewal tracking.
Logistics
& Dispatch Coordination
- Optimization of dispatch schedules and route planning.
- Tracking of in-transit shipments and delivery SLAs.
- Coordination with 3PLs and freight partners.
- Freight cost analysis and carrier performance review.
- Support for customs documentation and export compliance
Workforce
Productivity & HR Analytics
- Review of attendance, shift allocation, and labor utilization.
- Analysis of skill gaps and training effectiveness.
- Advisory on labor law compliance and safety norms.
- Workforce planning and headcount forecasting.
- Support for digital HR dashboards and analytics
Employee
Engagement & Retention Strategy
- Pulse surveys and sentiment analysis.
- Recommendations for incentive programs and career pathing
- Support for grievance redressal and workplace culture improvement
- Exit interview analysis and retention metrics.
- Leadership development and succession planning
Financial
Oversight & Cost Control
- Daily tracking of cost drivers: material, labor, energy, overhead.
- Identification of cost leakages and waste.
- Support for budgeting, variance analysis, and ROI tracking.
- Cost center performance review.
- Financial modelling for strategic decisions
Profitability
& Margin Analysis
- Product-wise and customer-wise profitability dashboards.
- Break-even and contribution margin analysis.
- Recommendations for pricing and cost rationalization.
- Fixed vs variable cost analysis.
- Profitability improvement roadmap.
Strategic
Planning & Business Intelligence
- Weekly strategic reviews with senior leadership.
- Monthly performance reports with trend and gap analysis.
- Advisory on automation, expansion, and market competitiveness.
- SWOT and PESTLE analysis.
- Long-term strategic roadmap development
Sales
& Demand Forecasting
- Analysis of historical sales, seasonality, and market trends.
- Forecasting models for demand planning and inventory alignment.
- Coordination with sales teams for order prioritization.
- Sales
funnel analysis and conversion tracking.
- Support for CRM integration and reporting
Customer
Order Fulfilment & SLA Monitoring
- Tracking of order status, delivery timelines, and SLA adherence.
- Resolution of delays and proactive customer communication.
- Root cause analysis of fulfillment failures.
- SLA breach reporting and escalation.
- Support for customer portal integration
Customer Satisfaction & VOC Analysis
- Monitoring of Net Promoter Score (NPS) and customer feedback.
- Support for complaint resolution and service recovery.
- Recommendations for customer experience enhancement.
- VOC trend analysis and action planning.
- Integration with customer support platforms
Tooling
& Asset Lifecycle Management
- Monitoring of tool wear, calibration, and refurbishment.
- Recommendations for tool upgrades or replacements.
- Asset tracking and depreciation analysis.
- Spare parts standardization.
- Tool performance benchmarking
Production
Scheduling & Capacity Planning
- Optimization of shift planning and machine allocation.
- Demand forecasting and schedule alignment.
- Identification of capacity constraints and expansion strategies.
- Simulation of production scenarios.
- Support for finite scheduling tools
Energy
Management & Sustainability
- Monitoring of energy consumption and carbon footprint.
- Recommendations for energy-efficient practices and green initiatives.
- Support for ISO 14001 and ESG reporting.
- Renewable energy feasibility analysis.
- Energy audit coordination
Waste
Reduction & Circular Economy Advisory
- Analysis of scrap, rework, and yield losses.
- Support for recycling, reuse, and waste segregation programs.
- Zero-waste roadmap development.
- Waste-to-value initiatives.
- Compliance with local waste disposal norms
Digital
Transformation & Industry 4.0 Strategy
- Evaluation of automation and smart manufacturing opportunities.
- Recommendations for MES, ERP, and IoT integration.
- Support for digital maturity assessment and roadmap.
- ROI analysis of digital investments.
- Cyber-physical system advisory
Cybersecurity
& Data Governance
- Advisory on data protection, access control, and backups.
- Risk assessment of digital infrastructure.
- Support for compliance with data privacy regulations.
- Incident response planning.
- Data classification and retention policy
Risk
Management & Business Continuity
- Identification of operational, financial, and reputational risks.
- Development of contingency and disaster recovery plans.
- Insurance coverage and legal safeguard advisory.
- Risk register maintenance.
- Scenario planning and stress testing
Vendor
& Partner Collaboration
- Facilitation of communication with suppliers and service providers.
- Evaluation of vendor performance and contract terms.
- Support for strategic alliances and co-development initiatives.
- Joint improvement plans.
- Partner onboarding and compliance
Leadership
Coaching & Governance Support
- Coaching for plant managers and department heads.
- Advisory on governance structures and decision-making protocols.
- Support for internal audits and policy development.
- Leadership competency assessment.
- Governance dashboard setup
Remote
Visual Supervision via HD CCTV
- Real-time visual oversight of production infrastructure.
- Remote monitoring of safety, quality, and material handling.
- Integration of camera feeds into daily Zoom sessions.
- Video-based diagnostics for anomalies and layout optimization.
- Archival footage analysis for incident investigation
Visual
Process Audits & Incident Review
- Remote walkthroughs for layout optimization and compliance checks.
- Support for visual SOP creation.
- Incident root cause analysis using video evidence.
- Safety violation detection.
- Visual verification of production quality.
Innovation
& R&D Advisory
- Support for new product development and prototyping.
- Benchmarking of emerging technologies and materials.
- Collaboration with academic and research institutions.
- Patent landscape analysis.
- Innovation funnel tracking
Management & Organizational Development
- Coaching for plant managers and department heads.
- Advisory on governance structures and decision-making protocols.
- Support for internal audits and policy development.
- Leadership competency assessment.
- Governance dashboard setup
Brand
Positioning & Market Intelligence
- Competitive benchmarking and SWOT analysis.
- Recommendations for product positioning and pricing strategy.
- Monitoring of market trends and customer preferences.
- Brand perception analysis.
- Support for marketing strategy alignment
Innovation
Pipeline & Technology Scouting
- Identification of disruptive technologies and process innovations.
- Support for pilot projects and proof-of-concept evaluations.
- Collaboration with startups and innovation hubs.
- Technology readiness assessment.
- Innovation ROI tracking
Remote
Internal Audit & Policy Review
- Review of SOPs, work instructions, and compliance documents.
- Support for internal audit planning and execution.
- Gap analysis and corrective action planning.
- Policy benchmarking and best practice alignment.
- Audit trail documentation and reporting
Remote
Engineering Change Management
- Review of ECNs and impact analysis across departments.
- Coordination of BOM updates and process revisions.
- Support for change approval workflows.
- Risk assessment of engineering modifications.
- Documentation control and version tracking