Manufacturing excellence

Help companies streamline operations, eliminate inefficiencies, and enhance productivity

In today’s dynamic business environment, manufacturing excellence is no longer just a goal - it is a necessity. Companies are under constant pressure to enhance efficiency, reduce costs, and maintain high-quality standards while adapting to new technologies. At the core of achieving operational excellence is enhancing every stage of the manufacturing process. This involves fine-tuning workflows, embracing automation, and fostering a culture of continuous improvement.

At KPMG in India, we help manufacturers unlock their full potential through our manufacturing excellence services, we focus on improving plant operations, from raw material management and production planning to quality control and process standardisation. By leveraging cutting-edge technology, data analytics and industry-leading practice, we help companies streamline their operations, eliminate inefficiencies, and enhance productivity.

Who is this for?

KPMG in India's manufacturing excellence services are designed for companies that have a significant value addition through manufacturing and are aiming to:

Overcome challenges such as high manufacturing costs, frequent downtimes, low Overall Equipment Effectiveness (OEE), inconsistent product quality, lengthy changeover times or workforce skill gaps impacting productivity

Re-evaluate their manufacturing strategy including make vs buy, plant – product mapping, consolidation of manufacturing locations

Expand their manufacturing capacities and design the factory of the future.

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We work with companies who are ready to address these challenges head-on and achieve transformative improvements in operational performance and competitiveness.

How can we help?

We help clients drive tangible improvements across their manufacturing operations. Our services lead to increased operational productivity enabling our clients to extract more value from their assets and workforce. Typical benefits achieved through our engagements are as below:

Manufacturing process improvement

Plant throughput enhancement by 30-50 per cent

Bottleneck OEE improvement by 25-40 per cent

Manpower productivity improvement by 30-50 per cent

Yield/quality improvement by 2-5 per cent

On time in full improvement by 30-40 per cent

Operating shifts improvement by 20-30 per cent

Change over time, batch cycle time reduction by 25–40 per cent

Plant overhead cost reduction by 8–10 per cent

Manufacturing lead time reduction by 20-30 per cent

Strategic improvement and capability building

Manufacturing strategy to support growth

Optimum enablement of shopfloor operations through technology and analytics

Enhanced shopfloor management and people capability

Continuous improvement mindset

We not only help clients address their immediate challenges but also lay the foundation for sustainable growth, equipping clients to adapt and thrive in a competitive market. With us, clients experience enhanced reliability, streamlined operations, and a strategic path forward, ensuring long-term resilience and success.

Why KPMG in India?

KPMG in India stands out as a trusted partner for manufacturing transformation due to our extensive industry experience, proven methodologies, and commitment to deliver measurable results. Here’s what sets us apart:

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Strong experience of manufacturing transformation

Rich experience of working with 500+ clients on manufacturing transformation across sectors over last two decades.

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Deep sectoral expertise

We have delivered multiple engagements involving assessment/implementation for across various industries like FMCG, automobile, metals and mining, heavy engineering (500+ engagements) and have deep understanding in each sector. Our project team is experienced in the nuances of the industries and is equipped to design and deploy optimal services for you.

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Strong expertise in driving transformative digital services

We have a team of 50+ seasoned professionals delivering tailored digital services with profound industry experience and technical acumen.

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Team with hands-on implementation experience

We have hand-picked the team with the right mix of various aspects of operations with sound hands-on experience of implementation to deliver results.

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Leveraging SMEs

KPMG in India has a strong SME board for each sector, and we leverage SMEs from various sectors to bring in learnings and faster delivery.

With KPMG in India’s manufacturing excellence services, clients gain a strategic partner dedicated to elevating their operations, enhancing competitiveness, and enabling sustainable growth.

Our Offerings

Manufacturing Excellence

Our range of manufacturing excellence services are designed to optimise your operations, enhance performance, and drive sustainable growth. From strategic alignment and performance enhancement to advanced analytics and smart solutions, we deliver tailored approaches to meet your unique business needs.

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Core offerings

Manufacturing strategy

Link business intent to manufacturing strategy

Demand supply assess

Global operating model

Global manufacturing and network footprint design

Off-shore versus onshore versus near-shore

Make versus buy decisions

Tax, trade and incentives.

Manufacturing performance

OEE improvement – availability, quality throughput (cycle time, changeover time, idle time) reduction

Optimising yield on RM

ESG Impact assessment

Decarbonisation and emissions

Emissions reconciliation.

Asset reliability

Transforming plant reliability including governance, skills development, failure elimination and change management

Enhancement of maintenance, repair and overhaul – including spare parts inventory levels, pricing, standardisation and cataloging.

Cost enhancement

Manpower, energy, utility cost, MRO and consumables etc

Consumption enhancement and value in ese of raw materials

Inventory versus OTIF

Machine rroduct calibration.

Planning and scheduling improvement

Forecasting

Inventory strategy

Capacity planning (RCCP, RvsC improvement)

Inventory norms

Campaign strategy.

Enablers/tools

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Management process and practices (SOPs, TPM, 5S, Lean, Six Sigma)

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Industry4.0 and SMART solutions (ERP MES, robotics, automation, reference architectures, IT OT integration)

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Industry 4.0 and advanced analytics (soft sensors, predictive and pprescriptive analytics, machine learning)

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Governance, change management, capability building, culture

Others – Frameworks/approaches

Institutionalising best demonstrated performance

Gather historical performance data and relevant variables. Suggest test run data gathering experiments, if needed.
Use advanced analytics for identifying operating regimes
Develop standard operating procedures (SOPs) based on analytical insights. Train staff and monitor adherence to new implemented SOPs.

High levels of asset performance management

Focusing on monitoring and improving the performance of individual assets
AI based early warning systems to predict failures
Increase asset availability by identifying and resolving issues before they impact business.

Process control reconstruct as a first line of attack

Analytics for tuning of control loops for process stability
Resolving control issues – stiction, hysteresis, CV/MV limits issues, move suppression issues etc.
Advanced process control landscape assessment
APC performance improvement for increased value realisation.

Soft sensorisation select AI/ML use case deployments

Provide measurements in tough, hasardous environments where traditional sensors cannot be installed or are too expensive to implement
Improvement in process control with additional information made available by Soft sensors
Reduction in manual work – field readings and laboratory work – result in reduced human errors and cost.

Deep industry and domain knowledge

Identifying bottlenecks and suggesting solutions to “move” the bottlenecks for incremental throughput benefits
In-depth process knowledge, supply chain understanding and operating experience
Energy efficiency improvements at equipment and plant level.

Instilling a data driven decision making culture

Encourage a data-first mindset:
Training and education for empowering individuals to make data-driven decisions
Communication and recognition of data-driven decision-making success.

Functional experts from IT/OT, data analytics, software engineering, IIoT and industry working together to drive problem solving, architecting solution and implementing it.

Transforming for a future of value

The KPMG suite of business transformation solutions help clients get to a more productive and sustainable future. The solutions are designed to address different client challenges and different parts of a business or a operating model. Each one contains rich insights and is underpinned by our leading transformation methodology.

KPMG digital transformation suite