Your factory is running all day—so why is production still slow?
(See how modern factory owners are scaling production without chaos, delays, or buying new machines)
Who This Is For?
- Factory Owner
- Second-generation Business Owner
- Plant Head or Production Manager
- Owner of a Mid-Size Manufacturing Unit
What Problems We Solve
Machines are running, but production is still slow
You’re losing hours every day and struggling to meet demand.
Orders get delayed again and again
Customers are getting frustrated — and you’re losing repeat business.
Too much rework and rejection
Wasted material, wasted labor, and lower profit margins.
Old systems and manual processes everywhere
You’re stuck in firefighting mode instead of growing your business.
Your team resists new ideas
You avoid making changes because you don’t want to create conflict.
Upgraded machines but same old problems
You’ve spent money, but operations still feel stuck.
Scaling feels like a risk
You want to grow, but the current setup just isn’t ready to handle more.
Changeover between batches takes too long
Your output drops and your team loses momentum
Factory layout and workflow are unstructured
Workers walk more than they work. Time is lost. Efficiency drops.
Every decision needs you
You can’t step away without things going wrong. It’s exhausting.
What Problems We Solve
Machines are running, but production is still slow
You’re losing hours every day and struggling to meet demand.
Orders get delayed again and again
Customers are getting frustrated — and you’re losing repeat business.
Too much rework and rejection
Wasted material, wasted labor, and lower profit margins.
Old systems and manual processes everywhere
You’re stuck in firefighting mode instead of growing your business
Changeover between batches takes too long
Your output drops and your team loses momentum.
Factory layout and workflow are unstructured
Workers walk more than they work. Time is lost. Efficiency drops.
Every decision needs you
You can’t step away without things going wrong. It’s exhausting.
Scaling feels like a risk
You want to grow, but the current setup just isn’t ready to handle more.
Your team resists new ideas
You avoid making changes because you don’t want to create conflict.
Upgraded machines but same old problems
You’ve spent money, but operations still feel stuck.
Case Studies: Real Results from Real Factories
Processing Rejection Reduced by 46%
- Problem
High rejection rate during fabric processing.
- Fix
Tracked daily defects and applied root-cause corrections.
- Result
Rejection dropped from 3.25% to 1.74%.
Stitching Output Increased by 25%
- Problem
Low daily output per tailor.
- Fix
Line balancing, SMED, and daily production boards.
- Result
Output rose from 162 to 203 pcs/day per tailor.
Chemical Wastage Cut by 55%
- Problem
Excessive chemical loss during dyeing.
- Fix
Ergonomic tanks, usage tracking, and process review.
- Result
Wastage reduced by over 55%, saving major costs.
Cutting Rework Down by 26%
- Problem
Too much fabric lost during cutting.
- Fix
Layout redesign and trimming the automation.
- Result
Rejection dropped from 1.59% to 1.18%.
Final Rejection Rate Improved by 40%
- Problem
Packaging defects and final QC failures.
- Fix
Standard inspections and team coordination.
- Result
Final rejection reduced from 1.22% to 0.74%.
₹1,37,99,677.50 Saved in Just 12 Months
- Across all improvements
Quality, productivity, layout, and resource use
- Result
₹1.25 Cr+ total savings without any factory expansion.
About Rajesh Marwah
Your Growth Partner in Manufacturing
With over 30 years of global leadership experience, I bring a practical blend of strategic insight and on-ground operational expertise to help manufacturing businesses scale, innovate, and lead with confidence.
Global Experience You Can Trust
I’ve held senior leadership roles at some of the world’s top companies:
- IKEA
- Samsung
- The Home Depot
- Nokia-Siemens Networks
My work has taken me across multiple geographies, cultures, and technologies, giving me a deep understanding of how operations succeed—or stall—at every level.
Proven Impact Across Manufacturing & Services
Over the years, I’ve led business transformation projects that resulted in:
- Higher productivity and throughput
- Shorter lead times and better on-time delivery
- Better product quality and fewer defects
- Significant cost savings across operations
I use practical tools like Lean Six Sigma, Kaizen, and TQM to help teams embed systems that drive long-term, measurable value.
Empowering the Next Generation of Factory Owners
As a certified Coach of Business Owners (Manufacturer), I work closely with factory owners and leadership teams, especially in family-run manufacturing businesses, to help them:
- Build scalable operational systems
- Improve profitability and sustainable growth
- Manage smooth generational transitions
- Adopt Industry 4.0 and smart manufacturing practices