- Business Strategy
A Sanitaryware Leader’s Operational Turnaround
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Industry
Sanitaryware Manufacturing
Location
Ahmedabad, India
Engagement Duration
5 months
Stakeholders
CEO, Plant Head, Ops, Production Planning, Procurement
The Client’s Challenge
A mid-sized sanitaryware manufacturer in Ahmedabad had built a strong regional presence, but operational inefficiencies were limiting scalability. While demand was rising, performance on the shopfloor told a different story.
Key issues included:
- Extended production lead times, resulting in frequent delivery delays and strained distributor relationships
- High work-in-progress (WIP) inventory, tying up working capital and congesting the factory floor
- Double-digit rejection and rework rates, particularly in glazing and finishing processes
- Unplanned downtime across kilns and casting lines, impacting throughput
- Fragmented planning processes, leading to last-minute schedule changes and firefighting
Despite steady sales, profitability was under pressure. Industry competitors were achieving leaner cost structures and faster turnaround times. The leadership team recognized that incremental fixes would not suffice—they needed a systemic transformation anchored in Lean principles.
Why the Client Chose Us
The leadership team selected Cogzion based on:
- Proven expertise in Lean transformations within manufacturing environments
- Hands-on, shopfloor-driven methodology, not just advisory frameworks
- Rapid diagnostic capability with clear, outcome-oriented roadmaps
- Strong change management approach, ensuring frontline adoption
- Track record of delivering measurable cost and productivity gains within months
Cogzion ability to combine strategic clarity with operational rigor differentiated the engagement from traditional consulting models.
Our Solution
Cogzion implemented a structured Lean transformation program across the plant, focusing on speed, waste elimination, and cultural shift.
- End-to-End Value Stream Mapping
We began with a comprehensive value stream mapping exercise across casting, drying, glazing, firing, and finishing.
- Identified bottlenecks responsible for significant throughput loss
- Mapped non-value-added steps contributing to excess movement and waiting
- Quantified cycle inefficiencies across production stages
This diagnostic revealed that over 30% of process time was non-value-adding, creating a clear opportunity for optimization
- Shopfloor Stabilization & 5S Deployment
A structured 5S rollout was implemented across critical production areas.
- Reduced material search time by over 40%
- Improved workplace organization and visual controls
- Enhanced safety compliance and reduced minor incidents
Standard work protocols were introduced to stabilize daily operations and reduce variability.
- Production Flow Optimization
To address high WIP and delayed output, Cogzion redesigned the production flow.
- Introduced pull-based scheduling mechanisms
- Balanced workloads across casting and glazing lines
- Reduced batch sizes to improve responsiveness
This improved flow significantly reduced congestion and improved line efficiency.
- Downtime Reduction & TPM (Total Productive Maintenance)
Frequent kiln and machine stoppages were addressed through TPM practices.
- Implemented preventive maintenance schedules
- Trained operators in autonomous maintenance routines
- Established downtime tracking dashboards
Within weeks, unplanned downtime showed a measurable decline.
- Quality Improvement & Root Cause Elimination
Rejection rates were tackled through structured root cause analysis.
- Introduced first-time-right quality checkpoints
- Standardized glaze thickness controls
- Implemented daily quality review huddles
This reduced rework cycles and improved finished goods consistency.
Impact Delivered
Within five months, the transformation delivered tangible and sustainable outcomes:
25–30%
Reduction in Production Lead Times
35% +
Reduction in WIP Inventory
Double-Digit Reduction
Rejection & Rework Rates
Significant Decline
Unplanned Downtime
On-Time Delivery Performance
Improved to industry-leading levels
Operating Margins Improved
Through structural cost reduction
Beyond metrics, the plant shifted from reactive firefighting to structured performance management.
Outcome Summary
By embedding Lean principles into daily operations, the sanitaryware manufacturer transitioned from an efficiency-constrained operation to a streamlined, performance-driven enterprise. The transformation unlocked capacity without capital expansion, strengthened distributor confidence through reliable delivery, and structurally improved margins.
More importantly, Lean became a capability—not a project. The organization now operates with a culture of continuous improvement, positioning it to scale sustainably in a competitive and cost-sensitive market.
Cogzion did not just improve processes—we helped build an operational engine for long-term growth.