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Boosted Plant Uptime and Profit Margins for an Indian Specialty Chemicals Manufacturer

Client Profile

A Gujarat-based specialty chemicals company serving B2B clients in the agrochemicals and pharmaceuticals industries. They operate two manufacturing plants with semi-automated infrastructure and serve mid-to-large domestic clients as well as select exports to Southeast Asia.

Business Need

Despite consistent demand, the company suffered from fluctuating plant efficiency, delayed production cycles, and underwhelming profit margins. The leadership engaged PBS to help optimize end-to-end plant operations, improve team accountability, and boost profitability without capex-heavy upgrades.

Challenges

  • Lack of standardized operating procedures across units
  • Redundant manual reporting causing lag in decision-making
  • Overlapping responsibilities among operations and logistics staff
  • Delays in procurement affecting production timelines
  • No real-time visibility into output vs. efficiency vs. wastage

Solution by PBS

PBS delivered a ground-level operational transformation strategy, focused on high-impact, low-cost initiatives:

  • Designed clear SOPs for each plant function — from raw material intake to finished goods dispatch
  • Implemented real-time production tracking using mobile-friendly tools
  • Streamlined internal communication flows to eliminate bottlenecks
  • Re-mapped procurement process to sync with production cycles
  • Introduced shift-wise performance monitoring and dashboard reporting

Approach

  1. Conducted a 2-week on-site audit at both plants
  2. Mapped current state workflows using swimlane diagrams
  3. Identified wastage hotspots through observational and digital data
  4. Trained floor supervisors on SOP implementation
  5. Installed performance scorecards linked to incentives

Technology/Tools Used

  • Zoho Creator – Custom workflow & reporting tools
  • Airtable – Shift and maintenance tracking
  • Excel Macros – Efficiency analysis and trend tracking
  • WhatsApp for Business – Fast team updates
  • PBS SOP Playbook – Proprietary template system for operational flow

Business Impact

Improvement in overall plant efficiency
Reduction in reporting delays and manual errors
Cost savings by aligning procurement and production
Faster product delivery timeline

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