- KKB Consulting

Services

1. Strategic Consulting

KKB Consulting collaborates with organizational leaders, including CEOs and business owners, to analyze their vision and key challenges. Through a comprehensive SWOT analysis, the firm assesses internal strengths and weaknesses while considering external market conditions. This structured approach enables the development of techno-economically viable strategies, followed by the formulation and implementation of actionable plans. Its impact can be seen in the case studies described below.

2. Turnaround and Transformation

Turnaround and transformation require an in-depth study of existing conditions within the organization and its circumstances. After thorough analysis, a turnaround strategy is developed and implemented. Examples of KKB Consulting’s work in this area are outlined in the following case studies:

2.1 Case Study: Turning Around a Large Textile Mill in Egypt from Cash Losses to Profits
- Limitations of Management:
  - No funds available for capital expenditures
  - Cannot reduce workers’ salaries
- Strategic Decisions & Implementation by KKB Consulting:
  - Optimized workforce: Reduced manpower from 7,000 to 3,000 without salary cuts, leading to 40% savings on transportation, canteen, dispensary, and other overheads.
  - Enhanced operational efficiency: Appointed specialists in spinning, weaving, processing, and stitching to improve cost-efficiency, production quality, and output.
  - Product diversification: Shifted the weaving mill’s focus to high-count, wide-width fabric and the stitching unit from garments to home textiles for export.
  - External sourcing for quality improvement: Procured high-count yarn externally to meet superior quality requirements.
  - Market expansion: Initiated international certification processes and export operations, significantly increasing revenue and profitability.
2.2 Case Study: Transforming Poor Quality to Best Quality
- KKB Consulting transformed a dye-intermediate plant burdened with poor-quality finished products by:
  - Market identification: Found and gradually sold the poor-quality stock.
  - Quality control: Rectified faulty lab testing procedures and increased testing points during production.
  - Process improvement: Implemented changes in the manufacturing process to improve product quality to international standards, enabling the company to become a leading exporter from India.
2.3 Case Study: Transforming a Problem into an Opportunity
- When a fire destroyed the distillation section of a factory, KKB Consulting turned the situation around by:
  - Reconstruction & enhancement: Rebuilt the distillation section with an improved design and increased capacity.
  - Insurance recovery: Secured reimbursement through insurance based on reinstatement value.
  - Supply continuity: Maintained customer supply by procuring finished products from the market.
  - Strategic pricing: Capitalized on market price increases due to supply disruption.
  - Proactive maintenance: Utilized downtime for essential maintenance, modifications, and cleaning.

3. Project Cost & Time Management

Our project cost and time management approach combines traditional methodologies (PERT, CPM, Gantt Charts) with our proprietary WPR technique, consistently delivering projects ahead of schedule and under budget.

3.1 Case Study: 60% Reduction in Project Cost and Time of a Dyes-Intermediate Plant
- KKB Consulting reduced project cost from Rs. 3 crores to Rs. 1.2 crores and project time from 2.5 years to 1 year by:
  - Technology integration: Combined American and European technologies, eliminating redundant processes to streamline manufacturing.
  - Design optimization: Eliminated outdated overdesign practices and adopted precise, standard-compliant designs.
  - Layout efficiency: Designed compact layouts, reducing the built-up area for the main plant, utilities, stores, and offices.
  - Innovative project management: Applied KKB’s proprietary WPR technique alongside traditional methods like Gantt Charts, PERT, and CPM.

4. Growth & Business Development

KKB Consulting assists organizations in maintaining relevance, efficiency, and growth in developing their business.

4.1 Case Study: Growth of 50% CAGR of a Dye-Intermediate Manufacturer
- Implemented the following:
  - Local market dominance: Expanded production capacity and captured a significant share of the local market.
  - Export growth: Improved quality to international standards and commenced exports.
  - Global trading: Expanded into international trading of raw materials and finished products.
  - Diversification: Diversified into the production and trading of other dye intermediates and chemicals.

5. Performance Improvement

KKB Consulting helps organizations continuously improve their performance. We identify both known and hidden areas for enhancement, ensuring sustained efficiency and growth.

5.1 Case Study: All-Round Process Improvement of a Solvent Extraction Plant
- Process conversion: Converted a batch-wise process into a continuous process by making minor modifications to reactors, settlers, and pipelines.
- Capacity enhancement: Increased capacity fourfold without significant capital investment.
- Cost savings: Reduced operational costs and saved time while sparing additional reactor and settler usage.
5.2 Case Study: Production Improvement of a Dye-Intermediate Plant
- Material handling: Eliminated production delays by outsourcing manual material handling to a contractor.
- Bottleneck resolution: Installed a hot air dryer to reduce the cycle time of the fusion reactor, significantly increasing overall production without costly additional equipment.
5.3 Case Study: Yield and Quality Improvement of a Dye-Intermediate Plant
- Process optimization: Increased stirrer RPM in the main reactor, improving both yield and product quality.
- Waste reduction: Reused washings from vessel cleaning in the main process, reducing material waste and improving yield.
- International standards: Modified production processes to meet international quality standards, resulting in higher yields and superior product quality.