Inventory Reduction Consulting

Practical, Measurable, and Sustainable Solutions by Greendot Consulting

Inventory Reduction Consulting – Free Your Cash, Improve Delivery & Boost Profits

Excess inventory is silent theft inside your business. Your profit is stuck in raw material, your cash is blocked in WIP, and your finished goods are waiting for a customer. Meanwhile, suppliers ask for payment, but you can’t raise invoices because material is lying idle—not moving.

This is a common struggle for mid-size manufacturers in India, especially those operating in engineering, auto components, plastics, chemicals, pharma, and packaging industries. The root problem? No inventory control system and no scientific planning methodology.

Greendot solves this.

Live Training Examples

What Problems Excess Inventory Creates

Problem	Real Business Impact
Raw material overload	Blocked working capital
High WIP	Process chaos + delays
Shortages despite high stock	Expediting costs
Wrong forecasting	Frequent urgent purchases
Supplier payment pressure	No cash for business growth
Warehouse overfilled	Space shortage & risk
Delivery delays	Customer dissatisfaction
Mixing MTO & MTS	Zero clarity in planning

Measurable Business Results We Deliver

KPI	Measurable Outcome
Inventory Reduction	30% – 60%
Working Capital Improvement	25% – 45%
Lead Time Reduction	20% – 40%
On-Time Delivery	90%+
Space Utilization	+25%
Cash Flow Strength	Strong & predictable
Team Planning Culture	Built & sustained

Outcome: Higher OEE, safer operations, improved productivity, and a workplace that runs like a well-oiled machine.

What Problems Excess Inventory Creates

Tool	How It Helps
ABC / FSN Analysis	Identifies fast-moving vs dead stock and controls money leakage
MRP & Material Planning	Ensures right material at the right time—no excess, no shortage
KANBAN System	Converts chaos into pull-based flow to reduce WIP
Value Stream Mapping (VSM)	Exposes bottlenecks that create excess inventory
Safety Stock Calculation	Eliminates guesswork in inventory decisions
Make-to-Order / Make-to-Stock Strategy	Stops overproduction and builds clarity
Heijunka (Load leveling)	Balances production to prevent pile-up
Cycle Counting	Improves stock accuracy and inventory control
Warehouse Layout & 5S	Increases space availability and visibility control
Lead Time Reduction Tools	Accelerates flow & reduces WIP holding

Each tool is not theory—we implement it practically on your shop floor to reduce inventory and free cash stuck in the system.

Measurable Business Results We Deliver

Step 1

Inventory Diagnosis

Identify hidden waste and cash blocks

Step 2

Planning & Control Design

Fix ordering system and production flow

Step 3

Material Management System

Implement KANBAN + reorder control

Step 4

WIP Control & Flow

Balance operations and lead time

Step 5

Governance & Review

Daily inventory dashboard + target control

Why Greendot?

Greendot is one of India’s most trusted Lean & Productivity consulting partners, helping businesses grow through systematic and structured improvement.

25+ years of hands-on industry experience
1000+ successful improvement projects
Experts in engineering, automotive, chemicals, plastics & packaging industries
Strong on planning, systems, and measurable business impact
Zero theory – complete implementation
We build capability in your team with hand-holding support