Factory of the Future engagements in Germany, South Korea and a greenfield site in Hyderabad, India — with outcomes measured against hard operational and financial metrics. We're also delivering active engagements in Egypt. Site names and proprietary system details are generalized to protect client confidentiality.
Challenge: One of the region's largest paper-products plants — manufacturing diapers and sanitary pads on lines running near 2,000 units a minute — was losing efficiency to frequent breakdowns and unplanned stops. High scrap, low yield and rising maintenance costs forced the company to import product from Japan at a loss just to meet demand.
What we did: Rebuilt the plant's daily management system around meaningful KPIs and a clear pillar structure, introduced an Equipment Ownership System with real accountability, and executed the Autonomous and Productive Maintenance pillars — backed by refreshed onboarding and training across every shift.
Outcome: Operating efficiency climbed from the low 60s to a world-class 90%, with major breakdowns eliminated entirely. Within 12 months the plant needed zero imports from Japan — and within 24 months it was exporting to Japan and other markets on the strength of its new cost base.
Challenge: A 2,000-person, 49-nationality campus — combining R&D, manufacturing and one of the company's largest distribution centres — was designated the global "Factory of the Future" prototype. But legacy work systems (PDCA, TBM, CIL, Centerlining) were too slow for the mandate, defect tracking was manual, and the site had no real-time feedback loop to run on.
What we did: Defined the site's Ideal State against a structured HPO framework, replaced annual strategy deployment with agile Strategy Sprints, and shifted from manual review boards to live AI dashboards. Predictive maintenance powered by machine learning and IoT sensors replaced manual defect tracking, and automation restructured teams around oversight and exception-handling rather than manual checks.
Outcome: Productivity rose 35% over three years and operating costs fell 25%, including major reductions in inventory carrying cost — delivering the company's highest-ever financial return, ahead of the previous ten years combined. All five HPO factors moved from below the 7.0 multinational average to above the 8.5 HPO benchmark.
Challenge: Fabric care plants in developing markets have traditionally been labor- and contractor-intensive, with packaging historically outsourced to contractor workforces. The mandate here was different: build a fully automated, contractor-free greenfield site capable of vertical start-up from day one — with no global precedent for touchless or lights-out operations in this market.
What we did: Ran Vendor Acceptance Testing to surface machine weaknesses pre-launch, defined set points for ramp-up, steady-state and ramp-down, and built vertical start-up strategies for lead and rollout lines. Backed it with structured technology transfer and training, automated quality checks from day one, and a defect-prevention checklist with cross-functional sign-off at every milestone.
Outcome: The plant achieved vertical start-up on day one with zero hiccups, running with 500 employees and zero contractors. Quality checks were 100% automated, cutting defects by more than 80% in the first month, and MTBF targets were surpassed — earning recognition as a Factory of the Future and one of the top-performing sites globally within two months.
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