Paradise Biryani

The worlds most famous Biryani brand wanted to explore new commissary locations across India for its new store opening plans. The commissaries were to be modelled in such a way that capex, opex, transportation, & other costs are optimized. More than 30 scenarios were analysed to come up with the most optimized scenario.

Key benefits:

• The final optimized scenario predicted two facilities with details like- manpower, size of facility, machine required, transport routes, machine utilization & costs.
• Gives management directionally right answer where to open new facility & of what size
• Increased service levels
• Optimized transportation costs
• Gives cost details related to capex, opex, manpower & transport. Also sizing, machinery & utilization is detailed out.

Epigamia

Epigamia entered the dairy market of India with a very niche product- yoghurt. India’s first Greek Yoghurt brand has gained popularity among the Indian urbanites. To make things easier, we have developed an Integrated Business Planning Tool. The tool is designed to regularly align plans between sales and supply sides of the business so that all parties are in sync with each other and can plan around key constraints.

Key benefits:

• Decision-making process that realigns the tactical plans for all business functions in all geographies to support the company's strategies, business goals, and targets.
• Helps reach consensus on a single operating plan to which executives of the management team hold themselves accountable and allocate the critical resources of people, equipment, materials, time, and money to most effectively satisfy customers in a profitable way.
• Identify bottlenecks to avoid hampering of future growth plans

Safedecor

Safedecor is into manufacturing decorative laminates and is one of the leading domestic players. With growth in their business the challenges have increased and their focus is on automation and less people dependence. We have helped them in their automation journey with many systems like ERP, Automated Production Planning, Distributor Collaboration, Safedecor Insights (AI powered BI) system.

Key benefits:

• Distributor Analytics wrt Sales, Targets, Performance, Service levels
• Increase in service levels by 15%
• Inventory reduction by more than 60%
• Reduction in dead stock by 80%
• Reduction in wastages by 5%
• Minimal manual interference in planning and avoiding the use of multiple excel sheets
• Reduction in manpower cost by 25%
• Distributor reduction in dead stock and optimization of their inventory
• Automated reports which are AI powered that helps management in taking decisions

Tata Steel, Jamshedpur

The pioneer of steel production in India, Tata Steel is one of the top ten steel makers in the world. It is also the world’s second most geographically diversified steel producer.

Simulation & Optimization Modelling for Future Capacity Analysis

We identified the bottlenecks in the current plant setup and developed an optimization model for handling the increasing capacities in the plant. We carried out a simulation study in the facility to develop the process.

Key benefits:

• Identified key bottlenecks in the logistics layout that can hinder expansion plans.
• Resource utilisation keeping in mind further expansions
• Queuing time and turn around time analysis
• Significant savings by identifying key bottlenecks
• Significant savings by identifying key bottlenecks

Tata Steel, Kalinganagar

Tata Steel wanted to study the potential capacity of the rail tracks designed for (Tata Steel Kalinganagar). At present, the layout has been developed for handling rakes for low MTPA. TSK has planned to augment the capacity to three times the current MTPA. Tata Steel wanted to conduct a simulation study to understand whether the proposed tracks and layout will prove adequate to handle rake movements for the enhanced capacity plan.

Key benefits:

• Quantification of current state layout and performance levels
• Resource utilisation keeping in mind further expansions
• Identified key bottlenecks in the logistics layout that can hinder expansion plans.
• Comparison of predictions from the Baseline model vs Future State simulation model
• Queuing time and turn around time analysis

Koppers (Major US Checmical Manufacturer), Rail Car Simulation

Koppers is a global producer of chemicals, carbon compounds, and treated wood products. It is based out of Pittsburgh, Pennsylvania. It has a global manufacturing and distribution network across continents. Koppers wanted to right size their rail car and plan future purchase based on simulation modelling.

Key benefits:

• Quantification of current state layout and performance levels
• Resource utilisation keeping in mind further expansions
• Identified key bottlenecks in the logistics layout that can hinder expansion plans.
• Comparison of predictions from the Baseline model vs Future State simulation model
• Queuing time and turn around time analysis

Alo (Major European Manufacturer of Light Industrial Equipment)

Alo is a major agriculture machinery supplier based out of Sweden. Alo wanted to rationalize their distribution network across Europe without impacting their service levels. The reason for realignment of their distribution network were to reduce the operating costs & inventory.

Key benefits:

• Detailed picture of cost and service level impact by country and customer developed for each scenario
• 45+ different supply chain scenarios were analysed to find the optimal solution
• The number of European distribution centers was consolidated from 9 to 2, thus reducing operating expenditure
• Approx. 45% reduction in inventory levels
• Reduction in annual supply chain costs of ~10-11%

Koppers (Major US Chemical Manufacturer)

Koppers is a global producer of chemicals, carbon compounds, and treated wood products. It is based out of Pittsburgh, Pennsylvania. It has a global manufacturing and distribution network across continents. Koppers wanted to right size their supply chain network, deployment of assets and resources in the supply chain, and the selection of various manufacturing, distribution processes and transportation modes in the supply chain.

Key benefits:

• 10% reduction in operating cost
• 15% reduction in capital assets
• Model validation for costs & service levels
• Comparative analysis of alternate supply chain configurations
• Recommendations on facility location and capacity, and on transportation lane and modes

Jubilant Foodworks (Domino’s pizza)

Jubilant Foodworks is the leading Quick Service Restaurant in India operating close to 1000 stores in India for Dominos Pizza. Jubilant Foodworks wanted to realign their distribution centre’s/manufacturing facility in order to incorporate their future growth plans without affecting their service levels. Network Optimization was used to find optimal location and size of the distribution centre/manufacturing facility taking into account financials, operating cost, inventories and service levels.

Key benefits:

• Identified right location for future distribution centres and size
• 15% Reduction in inventory
• 5% improvement in service levels
• Reduction in capex and operating costs
• Streamlined size for existing facility (distribution centre/manufacturing facility)