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      A leading integrated steel manufacturer operating across galvanised sheets, colour‑coated sheets, and pipes was facing increasing pressure to improve performance in a volatile demand environment. Fragmented processes, limited digital enablement, and lack of real‑time visibility were constraining the organisation’s ability to drive sales growth, optimise production, and reduce inventory.

      KPMG in India collaborated with the client to enable business process improvement through digital automation-bringing transparency, discipline, and measurable outcomes across the value chain.

      The challenge

      The client’s operating environment was characterised by complexity and rapid decision cycles, with multiple constraints:

      • Demand volatility resulting in misalignment between sales, production, and inventory
      • Unplanned downtime and reactive decision making on the shop floor
      • Absence of standardised KPIs to monitor performance across functions

          

      • High ageing WIP inventory across raw materials and finished goods
      • Limited digital reporting and dependence on manual data consolidation

          

      The client needed to improve sales execution and production throughput, while simultaneously reducing costs and improving visibility across operations.

      Our approach

      KPMG in India delivered an end‑to‑end digital process improvement programme, focused on diagnostics, automation, and governance.

      Process diagnostics and KPI standardisation

      Conducted curated diagnostic workshops across sales, procurement, production, and maintenance

      Mapped end‑to‑end processes and decision flows

      Identified and standardised 300+ L1/L2 KPIs across the value chain.

      Data management and automated reporting

      Designed a centralised data platform integrating automated and manual data sources

      Developed 100+ automated Power BI dashboards and reports

      Enabled role‑based performance views and drill‑down analysis

      Built internal capability through structured user training.

      Throughput improvement and cost optimisation

      Identified 25+ high‑impact digital and AI‑led opportunities

      Prioritised initiatives focused on sales acceleration, FG throughput, and inventory reduction

      Developed business cases and charters outlining value potential and implementation roadmap.

      Governance and PMO enablement

      Established a PMO structure to monitor progress against targets

      Enabled structured reviews, risk escalation, and dependency tracking

      Supported stakeholder alignment and decision‑making cadence.

      Process diagnostics and KPI standardisation

      Conducted curated diagnostic workshops across sales, procurement, production, and maintenance

      Mapped end‑to‑end processes and decision flows

      Identified and standardised 300+ L1/L2 KPIs across the value chain.

      Data management and automated reporting

      Designed a centralised data platform integrating automated and manual data sources

      Developed 100+ automated Power BI dashboards and reports

      Enabled role‑based performance views and drill‑down analysis

      Built internal capability through structured user training.

      Throughput improvement and cost optimisation

      Identified 25+ high‑impact digital and AI‑led opportunities

      Prioritised initiatives focused on sales acceleration, FG throughput, and inventory reduction

      Developed business cases and charters outlining value potential and implementation roadmap.

      Governance and PMO enablement

      Established a PMO structure to monitor progress against targets

      Enabled structured reviews, risk escalation, and dependency tracking

      Supported stakeholder alignment and decision‑making cadence.

      The impact

      KPMG in India combined deep manufacturing expertise, digital enablement capabilities, and programme governance to help the client make process improvement measurable. The programme delivered tangible, time‑bound outcomes:

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      20–30 MT/day increase in production throughput through bottleneck resolution

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      INR3 crore+ cost reduction, delivered within 3–5 months

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      25 per cent reduction in ageing WIP inventory across RM and FG

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      Real‑time visibility enabled through 100+ automated dashboards

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      Improved decision discipline across sales, operations, and supply chain

      Key Contact

      Amit Bhargava
      Amit Bhargava

      National Leader, Metals and Mining

      KPMG in India

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