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INDUSTRY

Manufacturing in Secondary Sector

TECH STACK

Design Tool

Canva

Analyst Tool

MS Excel

This project involved analyzing a Fabricator company's end-to-end production capabilities to determine whether the company could fulfill a high-volume, time-sensitive order from Dhanashree Forge Ltd. The goal was to assess daily processing capacity under variability, identify constraints, and evaluate cost-effective alternatives such as overtime or workforce reallocation to meet delivery commitments while maintaining quality and profitability.

ROLES

Strategy Consultant

Operations Analyst

Marketing Strategist

COLLABORATORS

Aashi Jain

Akankshya Priyadarshini

DELIVERABLES

Cost per piece reduction

Production capacity optimisation

Working Hours optimisation

TIMELINE & STATUS

2nd Runner up

Completed

THE WHAT

To supply 500 finished components weekly for ten weeks to Dhanashree Forge—a reputed domestic and global supplier. The production line followed a five-stage process involving machining, heat treatment, finishing, and quality packing. Each stage had specific time and labor requirements, variability in processing times further complicated capacity estimation.

THE WHY

The large order created a tough trade-off between controlling costs and maintaining humane labor conditions. Meeting the demand either required expensive additional labor or pushed existing workers into excessive overtime. Despite these challenges, the opportunity to partner with Dhanashree Forge promised long-term benefits, making it critical to find a sustainable and balanced fulfillment strategy.

THE HOW

We began by breaking down and quantifying the problem to understand the company’s current capacity and constraints. After evaluating standard industry solutions—like buffer stock estimation at 95% confidence, extended workdays, and additional workforce deployment—we identified their limitations in this specific context. To overcome these, we developed a custom approach: the Trapezoidal Matrix Method, which is discussed in this case study.

THE HIGHLIGHTS

PROBLEM STATEMENT

PROBLEM BREAKDOWN

INITIAL CONDITIONS

TRAPEZOIDAL MATRIX METHOD

IMPACT