AUTOMOTIVE

Automotive Industry is considered the key driver of growth of Indian Economy and it’s true globally too. It all started in India with the opening of markets on 1991 and marked the end to rule of ‘License Raj’. In order to be profitable and stay competitive, auto OEMs and suppliers need to address the key Supply Chain and Logistics challenges due to product complexity, customer expectation and safety regulations. These issues are further fueled by cost pressures and overcapacity.

Capability – Manufacturing Planning, Design & Implementation Services

1. S&OP (Sales & Operations Planning) – Setup and Management

We establish a robust S&OP framework that integrates demand forecasting, supply planning, inventory strategy, and executive alignment to create a unified planning process. The service ensures cross-functional transparency, agility in decision-making, and reliable production and sales outcomes.

Nature of Projects / Engagement Types:

• Greenfield or brownfield S&OP setup for automotive OEMs/Tier-1 suppliers
• Monthly S&OP governance implementation
• Integration of demand planning with production and procurement
• S&OP maturity enhancement and process stabilisation

2. Plan for Every Part (PFEP) – Design & Implementation

We design PFEP systems from the ground up, detailing every material attribute—packaging, routing, storage, replenishment method, handling frequency, supplier integration, and consumption patterns—to enable precise material flow across the value chain.

Nature of Projects / Engagement Types:

• PFEP creation for new vehicle programs or plant expansions
• PFEP digitalization and central database development
• Re-engineering of existing PFEP for improved flow and inventory accuracy
• Packaging and material-handling optimization studies

3. Storage Design & Optimization (RM, Supermarkets, Semifinished, FG, Temporary Storage)

We design efficient material storage solutions covering raw materials, in-process goods, finished goods, and short-term buffers. The approach balances space utilization, throughput, safety, and material accessibility to align with manufacturing flow and customer delivery patterns.

Nature of Projects / Engagement Types:

• Greenfield and brownfield warehouse layout design
• Supermarket design aligned with pull systems and takt time
• Temporary storage and staging area optimization
• Inventory zoning, slotting, and footprint reduction initiatives

4. Parts Presentation & Line-Side Material Design

We design the complete approach to presenting parts to assembly lines—including storage concepts, line-side feeding, point-of-use racks, visual presentation, and ergonomic considerations—to maximize efficiency and reduce waste.

Nature of Projects / Engagement Types:

• Line-side storage and parts presentation design for new assembly lines
• Optimization of racks, trolleys, and sequencing stations
• Point-of-use delivery systems for high-rotation and critical components
• Packaging-to-line interface improvement

5. End-to-End Replenishment Strategy Design

We develop comprehensive replenishment strategies for manufacturing environments, using approaches such as order-specific sequencing, Kanban, Two-Bin systems, and hybrid models. The goal is to ensure uninterrupted production with optimal inventory levels.

Nature of Projects / Engagement Types:

• Kanban system deployment for high-volume automotive components
• Order-specific sequencing strategy implementation
• Two-bin system for fast-moving consumables
• Replenishment system redesign during model changeovers or capacity expansions

6. Material Requirements Planning (MRP) – Setup, Optimization & Management

We establish or refine MRP frameworks covering BOM accuracy, lead times, planning parameters, and data governance to enable precise procurement and production scheduling. This reduces stockouts, excess inventory, and planning inconsistencies.

Nature of Projects / Engagement Types:

• MRP setup for new production lines or plants
• MRP parameter optimization (safety stock, reorder points, lead times)
• MRP-to-S&OP integration
• Ongoing MRP governance and data cleansing initiatives

7. New Process Design (DMEDI), Process Improvement (DMAIC) & SOP Implementation

Using proven Six Sigma methodologies, we design new processes through DMEDI and optimize existing ones through DMAIC. Standard Operating Procedures (SOPs) are created and institutionalized for consistency, training, and audit readiness.

Nature of Projects / Engagement Types:

• DMEDI-based design for new manufacturing or logistics processes
• DMAIC-based problem-solving and defect reduction
• SOP framework creation and rollout for production/quality/logistics
• Audit readiness through standardized documentation

8. Automotive Line Balancing, Efficiency Improvement & Line Optimization

We analyze, design, and optimize assembly or machining lines to achieve optimal line balancing, cycle time reduction, throughput enhancement, and waste elimination.

Nature of Projects / Engagement Types:

• Line balancing for new vehicle platforms
• Cycle time studies and throughput optimization
• Operator work element analysis and ergonomic improvements
• Bottleneck analysis and continuous improvement deployment

9. Quality Management System (QMS) Implementation for Automotive

We implement comprehensive QMS frameworks aligned with IATF 16949 and automotive best practices. The focus is on defect reduction, process control, documentation, and audit compliance.

Nature of Projects / Engagement Types:

• QMS setup for new plants or suppliers entering the automotive sector
• IATF 16949 readiness and gap closure
• Quality assurance framework design (APQP, PPAP, FMEA)
• Internal audit system setup and governance

10. MMOG/LE Audit & Transformation Support

We support automotive suppliers in achieving world-class material planning and logistics performance through the MMOG/LE (Materials Management Operations Guideline / Logistics Evaluation) framework. Our service covers readiness assessment, gap identification, corrective action planning, and full transformation support to help organizations achieve higher MMOG/LE ratings (A or B) and ensure compliance with OEM customer requirements.
We strengthen end-to-end material flow, logistics controls, supplier management processes, inventory accuracy, and digital traceability to enhance reliability and operational excellence.

Nature of Projects / Engagement Types

• MMOG/LE self-assessment and detailed gap analysis for all 6 chapters (Strategy & Improvement, Work Organization, Customer Interface, Production & Supply Control, Supplier Interface, Logistics & Customer Support)
• Development of corrective action plans and transformation roadmaps to achieve A-level compliance
• Implementation support for logistics process improvements, inventory accuracy, traceability, and replenishment control
• Training and capability building for planning, logistics, and supply chain teams on MMOG/LE standards
• Pre-audit readiness checks and documentation preparation for OEM/OESA audits
• Integration of MMOG/LE requirements into existing QMS, S&OP, PFEP, and supply chain processes
• Digitalization and automation of logistics processes to meet MMOG/LE criteria (forecasting, ASN/EDI, supplier scheduling, inventory control, material flow tracking)

11. Lean & Six Sigma Transformation

We lead continuous improvement initiatives to reduce waste, stabilize processes, and drive operational excellence through Lean tools and Six Sigma methodologies.

Nature of Projects / Engagement Types:

• Lean transformation programs at plant or enterprise level
• Kaizen events, waste elimination workshops
• Six Sigma problem-solving projects (Green Belt/Black Belt)
• Capability development and training programs

12. Value Stream Mapping (VSM) & Transformation

We map, analyze, and redesign value streams across manufacturing, logistics, and order execution processes to establish flow, reduce lead times, and improve responsiveness.

Nature of Projects / Engagement Types:

• VSM creation for entire plants or specific value streams
• Future-state design and transformation roadmap creation
• Logistics flow simplification and lead-time reduction
• Integrated material and information flow improvements

13. Process Design & Re-engineering Using BPMN 2.0

We design, map, and optimize business processes using BPMN 2.0 industry standards to enable clarity, automation, and effective communication across business functions.

Nature of Projects / Engagement Types:

• End-to-end business process modeling for manufacturing and supply chain
• Process re-engineering to eliminate redundancies
• Business process automation readiness
• Data and workflow alignment for ERP/MES integrations

14. Process Standardisation & Simulation using Standard Work and Digital Tools

We create standardized work models and simulate processes digitally using tools like Camunda, Signavio, and Miro to ensure consistency, performance predictability, and scalability.

Nature of Projects / Engagement Types:

• Standard work definition for assembly and logistics operations
• Simulation of future-state processes for decision-making
• Workflow automation using BPM platforms
• Digital twins for process evaluation and optimization

15. KPI Framework, MIS Implementation & Performance Management Systems

We design and implement management information systems, including KPI frameworks, goal-setting mechanisms, operational definitions, benchmarking models, and measurement methodologies for data-driven decision-making.

Nature of Projects / Engagement Types:

• Maturity assessment and redesign of MIS & reporting systems
• KPI/metric framework design for plant, supply chain, or quality
• Balanced scorecard and benchmarking setup
• Digital dashboards and metric governance deployment

16. RPA Automation in Manufacturing Planning, Processes & Execution

We deploy Robotic Process Automation (RPA) solutions to streamline repetitive, rule-based activities across planning, procurement, production, logistics, and quality functions.

Nature of Projects / Engagement Types:

• Automation of MRP runs, inventory reconciliations and planning parameter updates
• Automated generation/distribution of production schedules and reports
• RPA bots for supplier follow-up and delivery adherence
• Automation of quality documentation and audit workflows
• RPA-assisted production booking and ERP/MES system updates

17. Low-Code Automation through AI/ML & IoT Integration

We implement low-code platforms powered by AI/ML and IoT capabilities to rapidly digitize and automate manufacturing planning and execution processes.

Nature of Projects / Engagement Types:

• Low-code applications for planning workflows and production control
• AI/ML-driven forecasting and predictive analytics
• IoT-enabled dashboards for machine utilization and line performance
• Digitization of PFEP, replenishment, and S&OP workflows
• Mobile apps for shop-floor visibility and alerts