Clientele

Why Manufacturing Companies Need Management Consulting

  • India’s manufacturing sector contributes ~17% to GDP and is targeted to reach 25% under the Make in India initiative. Yet most mid-market manufacturers operate without documented SOPs, standardized quality systems, or integrated ERP platforms.

Manufacturing Industry Challenges

  • High Production Costs & Waste: Rising raw material costs, energy expenses, and production waste eat into margins. Without structured process analysis, manufacturers often operate at 15-25% below optimal efficiency. PKC’s lean consulting and BPR methodology sets up processes to track the costs & wastage across modules from procurement to dispatch.
  • Manual & Disconnected Processes: Many Indian manufacturers still rely on Excel-based tracking, paper-heavy quality checks, and siloed departments. This leads to delayed MIS, inventory mismatches, and poor coordination between production, stores, and dispatch. PKC’s SOP & Process Mapping service documents every workflow, and our Business Process Automation practice connects systems end-to-end.
  • ERP Implementation Failures: Selecting the wrong ERP - or implementing the right one poorly is one of the costliest mistakes a manufacturer can make. PKC has implemented 30+ ERP systems (SAP, Oracle, Tally, Zoho, and niche manufacturing ERPs) with a methodology that covers requirement mapping, preparing BRD, vendor evaluation, data migration, user training, and post-go-live support.
  • Quality & Compliance Gaps: ISO certifications, BIS standards, PLI scheme compliance, and customer audits demand documented processes and continuous improvement. PKC’s Business Excellence (COE model) and Lean Six Sigma consulting builds quality into every process not as an afterthought, but as a core operational discipline.
  • Scaling Without Losing Control: Growing from ₹50 crore to ₹500+ crore requires fundamentally different systems, controls, and org. structures. PKC has helped manufacturers navigate this transition through structured BPR, technology-enabled MIS dashboards, and Centre of Excellence models that sustain improvements long after the consulting engagement ends.

PKC Services for Manufacturing

Business Process Re-engineering (BPR)

End-to-end process redesign for production planning, inventory management, procurement, quality control, and dispatch. We map your current state, identify bottlenecks, and implement redesigned workflows with measurable KPIs.

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SOP & Process Mapping

Document every process from raw material receipt to finished goods dispatch. Our SOPs become the foundation for training and audits.

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Business Process Automation

Automate purchase orders, production scheduling, quality inspections, and MIS reporting. We’ve delivered many automation projects significantly reducing manual effort and improving efficiency.

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Business Excellence & Lean Six Sigma

Implement Continuous Operational Excellence programmes with process excellence teams to continuously train/re-train stakeholders, improve business visibility, facilitate review meetings, and build a culture of continuous improvement.

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ERP Software Implementation

Vendor-agnostic ERP implementation, we implement the right system to your scale, train your team, and ensure successful adoption.

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Our Success Stories

Invoice Time Cut from 3 Hours to 30 Minutes: A Process Overhaul for an Aluminum Extrusion Services Firm

  • Fixed unstructured accounting with cost-center and expense-based tracking in Tally → 44% reduction in unwanted ledgers.
  • Automated GST/PO-to-invoice process, eliminating manual filing errors → penalties reduced to zero
  • Systematized payment/receipt tracking in Tally → 60% cut in emergency cash usage, 70% of transactions shifted to bank
  • Built SO-to-invoice workflow in Tally → invoice processing cut from 2–3 hrs to 30 min per invoice
  • Added order-specification intake and blacklist controls → reduced sales returns and improved order prioritization via outstanding-order visibility

From Stock-Outs to Real-Time Visibility: How PKC Boosted Output by 25% for a ₹80Cr PET Bottle Manufacturer

  • Fixed poor production planning causing FG stock-outs by implementing structured production planning for optimal stock levels → average daily production increased from 62K to 78K units (~26% increase)
  • Resolved order fulfillment gaps causing customer dissatisfaction and returns, via a dedicated sales order tracking and fulfillment mechanism → 95% increase in order fulfillment ratio
  • Reduced management's operational involvement by introducing SOPs and an MIS system for better information flow → 6-hour reduction in daily management involvement, with real-time stock data now accessible
  • Introduced a QC process to address sales returns from quality issues → defect rate reduced from 1.5% to 0.7% (over 50% reduction)
  • Fixed job work production gaps with proper systems and processes → job work order and receipt variance now tracked and reported to management, closing a prior visibility gap

Ready to Transform Your Manufacturing Operations?

Listen to our clients

Apex coconuts, one of the largest vertically integrated coconut processing company in south east asia, was facing issues with handeling a lot of leads and turning of leads to deal. Upon their meeting with the PKC team, PKC analysed the business and issues. Gokul Shrinivasan, the CMO of Apex coconut said-“The PKC team analysed all the issues, communicated them to me and the solutions as well. PKC also implemented CRM for me that helped me analyse the leads better, and thus have a more worry-free process. PKC has helped me analyse all information and turn it into prsopects. We look forwad to engage PKC into procurement and logistics and accounts domain. We really recommend the PKC team”
Gokul Shrinivasan

Apex coconuts

"Our collaboration with PKC Consultants has added incredible value to our ERP implementation Project. Leveraging their experience and knowledge helped us Go Live on time at Sundaram Composites, while critical activities like Requirement gathering, Testing, User training and Documenting procedures are addressed in advance. <br><br> Their contribution to the development of structured way for assessing the Implementation partners, Understanding the Business processes and putting up checks and balances as appropriate was critical in meeting the Digital Initiatives which we combined with our ERP Implementation."
Thirumalai G

Head - India Operations

"The Internal Audit Assignment carried out by your team was in a very Structured manner and the Quality of Service is excellent."
CA Sampathkumar D

CFO, IndianOil LNG Private Limited

“Thank you for all the support you and team provided!!”
Madhan S

Senior Director

“You and the entire PKC team have been an instrumental part of the journey. Thank you!”
Atul Sahai

SaaS Strategy & Operations

"PKC helped us launch our 65000 sq.ft. retail store in Chennai from the very start. Results were clearly evident. To say the least, their systems have ensured that the store operates in an auto mode format. We strongly recommend PKC . As a Team, they understand client's requirements and fulfils them in the best possible manner."
Rahul Bhora

CEO, Madras Super Store

"We did not have control of our expenses, due to the sheer size of our 40 store operations. With PKC's insights, we are now in control of costs. The best thing about PKC is they are ready for change & work as per the clients need, even though it's out of their way."
Raakesh Ramanand

Managing director, Consolidated retail

"Prakash Kochar & Co Chartered Accountants" were recommended to us a number of years ago and we certainly have no regrets about moving to them. Work is carried out efficiently, professionally and to a very high standard. We are happy in the knowledge that Prakash Kochar & Co will always do their best to look after our business and drive it forward. Anyone in the retail industry looking for excellent customer service should look no further."
M.Rajalingam

Group Chairman, MSR Group

"When it comes to consulting, auditing and other vital business services, there are many that talk a good game. PKC Consulting helps you make remarkable happen. They took the time to understand who we are and what we require; and provided us with customized yet apt solutions to choose and implement for the better. Their input and direction have proved to be instrumental in obtaining our daily objectives and in time adding value to the growth of the company. They have optimized our sales and purchase procedures, streamlined our accounting structure and enabled us with real-time data, making day-to-day operations almost seamless. And the results are beyond impressive. We wholeheartedly recommend PKC Consulting to everyone we know."
Ahmed Thariq

CEO, National Aluminium

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    Frequently Asked Questions

    A management consultant analyses your production processes, supply chain, quality systems, and organizational structure to identify inefficiencies. They then design and implement solutions to streamline processes, improve quality, and enable scalable growth.

    The consulting timeline depends on scope. A focused SOP-mapping engagement for a mid-sized manufacturer may take 6-8 weeks, while a full-scale BPR + ERP implementation can range from 16-24 weeks.

    Manufacturing businesses without proper controls typically have 3–10% inventory discrepancies. PKC’s inventory management framework typically reduces this significantly, resulting in lakhs of savings annually.

    PKC works with manufacturers across the spectrum - from ₹10 crore turnover SMEs to ₹500+ crore enterprises. Our engagement models scale to fit: focused process audits for smaller firms, and multi-phase transformation programmes for larger ones.

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