
INDUSTRY
TECH STACK
ROLES
COLLABORATORS
DELIVERABLES
TIMELINE & STATUS
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 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.
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
