Driving Measurable Performance on the Shop Floor & Across Projects
Manufacturing and project-driven organizations often struggle not because of lack of capital or technology, but due to inefficiencies in execution, misalignment between functions, and under-optimized processes.
At AYDAA, we partner with leadership teams to unlock productivity, improve operational efficiency, and create sustainable performance improvements—without unnecessary capex.
Productivity Enhancement
We identify hidden capacity, eliminate bottlenecks, and improve throughput across production lines and project execution.
Key Interventions:
- Line balancing & capacity optimization
- Bottleneck identification & debottlenecking
- Output improvement without capex
- Productivity benchmarking vs best-in-class
- Daily management systems (KPIs, dashboards, reviews)
Outcome: Higher output per shift, Improved manpower utilization, Faster cycle times
Operational Efficiency Improvement
We streamline processes to reduce waste, rework, and delays across manufacturing and project environments.
Key Interventions:
- Process mapping & waste elimination (Lean principles)
- SOP standardization & compliance
- Cross-functional workflow optimization
- Reduction in downtime & rework
- Project execution efficiency improvement
Outcome: Lower operating costs, Improved process discipline, Predictable execution
Inventory & Working Capital Optimization
Excess inventory and shortages both hurt profitability. We help strike the right balance.
Key Interventions:
- Inventory diagnostics (RM, WIP, FG)
- Demand–supply synchronization
- Safety stock & reorder level optimization
- Slow-moving & obsolete inventory reduction
- Inventory governance frameworks
Outcome: Reduced working capital blockage, Improved material availability, Lower carrying costs
Sales & Manufacturing Alignment (S&OP Enablement)
Misalignment between sales forecasts and manufacturing plans leads to firefighting. We bring structure and predictability.
Key Interventions:
- •Sales & Operations Planning (S&OP) framework
- •Forecast accuracy improvement
- •Demand planning & production planning integration
- •Order prioritization & fulfillment optimization
- •Monthly cross-functional review cadence
Outcome: Improved service levels, Reduced last-minute changes, Better customer commitment adherence
Time & Motion Studies
We scientifically study how work is done to remove inefficiencies and improve labor productivity.
Key Interventions:
- •Detailed time studies for operations & processes
- •Motion analysis to eliminate non-value activities
- •Standard time setting & productivity norms
- •Manpower optimization & layout improvement
- •Basis for incentive & performance systems
Outcome: Higher labor productivity, Standardized operations, Fair and transparent performance benchmarks
Cost Optimization & Margin Improvement
We focus on structural cost improvements, not short-term cost cutting.
Key Interventions:
- •Cost structure analysis (fixed & variable)
- •Yield & scrap reduction
- •Energy & utility cost optimization
- •Make vs buy decisions
- •Vendor & sourcing efficiency improvement
Outcome: Sustainable margin improvement, Reduced cost per unit, Improved competitiveness
