Operations & Supply Chain · Services

Core Process Redesign for a Mid-Market Firm

Client / Manufacturing-adjacent services company (600 employees)Location / Chennai≤24 hrs to shortlist
The Challenge

The company had grown from 200–600 people through organic hiring and two acquisitions, and had never stopped to standardise how work actually got done. Each site had its own approach to order management, its own escalation path, its own way of handling errors. New employees learned the job by watching whoever sat next to them, which meant the errors spread as consistently as the good habits. Managers spent their days correcting mistakes that shouldn't have happened. The CEO used the phrase 'firefighting' in three consecutive board presentations.

The Approach

A four-week process diagnostic across five core functions, not to document every variation, but to rank 42 identified gaps by error-to-output impact. The redesign was executed in phases, starting with the three functions where errors were costing the most. Process guides were written by the people doing the work, not by the consultants. That's the only way they actually get used.

The Outcome

Operational output increased 15% within six months without additional headcount. Order management error rates fell 68%. The more important change was what the function heads stopped doing: three of five said they had time for forward planning for the first time in over a year.

15% output increase | Order error rate down 68%
+15%
Output Increase
-68%
Error Rate
Zero
Headcount Added
Client
Manufacturing-adjacent services company (600 employees)
Sector
Services
Location
Chennai
Domain
Operations & Supply Chain
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