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INDUSTRY
Manufacturing in Secondary Sector
TECH STACK
Design Tool
Canva
canva
Analyst Tool
MS Excel
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
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PROBLEM STATEMENT
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PROBLEM BREAKDOWN
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INITIAL CONDITIONS
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TRAPEZOIDAL MATRIX METHOD
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IMPACT
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