“Tenali… customers are shouting about delays. Production says jobs are moving. Stores say material is issued. Inspection says work is pending. But nobody can tell me where a job actually is!” Tenali smiled. “Then your factory has production activity… but no production visibility.” “Tell me: How many active jobs are running today?” “About 137.” “How […]
Maharaj frowned at the report. “Tenali… our daily capacity is 500 units.But we’re stuck at 350. Machines are fine. Workers are present.Where are 150 units disappearing?” Tenali smiled.“Let’s investigate.” “Tell me; do workers know the daily target?” Maharaj paused. “Not exactly.” “Are design changes communicated daily?” “Sometimes… through supervisors.” “Do you track repeated errors?” “No […]
“Tenali, our new mixer grinder is selling fast. 5,000 units in a month! Yet… losses of ₹2,50,000. How?” Maharaj asked Tenali. Tenali answered immediately, “Let’s investigate the numbers, Maharaj. Selling Price: ₹2,000 per unit Current Cost: ₹2,050 per unit Expected Volume (initial plan): 8,000 units Actual Volume: 5,000 units Fixed Costs: ₹40,00,000 You priced first… […]
“Tenali, profits are flat despite stable sales?” Maharaj was curious and sad at the same time. “Exactly, Maharaj. Revenue is ₹50 lakh every month. But costs? stuck at ₹44 lakh.” Tenali leaned forward. “Maharaj, please show me last 3 months’ data.” Maharaj opened the sheet: Labour cost: ₹12 lakh → ₹12.2 lakh → ₹12.4 lakh […]
“Maharaj, your plant runs 12 hours daily. Still profits are flat?” Maharaj replied, “Yes! Machines are fully occupied.” Tenali asked for data. “Here’s what I see: • Machine A utilisation: 95% • Machine B utilisation: 52% • Average order delay: 18 days • Overtime cost: INR 22,000/month • Pending orders: INR 3.6 lakh” Maharaj said, […]
“Maharaj, which is your best product?” Tenali asked Maharaj Maharaj smiled. “Product A! 55% of our sales. Clear winner.” Tenali raised an eyebrow. “Or… clear illusion?” Maharaj frowned. “What do you mean?” “Let’s play a quick game,” Tenali said. “Tell me the numbers.” Maharaj replied: “Product A → 4 machine hours, INR 200 margin Product […]
Maharaj sounded confident. “Tenali… we pushed sales this quarter using heavy discounts. Revenue jumped from 80 Lakhs to 1.1 Crore.” “And profit?” Tenali asked Maharaj paused. “…fell from 16 Lakhs to 9 Lakhs.” Tenali nodded. “Let us see the numbers clearly: Selling Price reduced: from INR 500 INR 440 Variable Cost: INR 380 Contribution per […]
Maharaj looked disturbed. “Tenali, my friend Mr. Cashew made a profit of 25 lakhs in his business… yet he is struggling to pay salaries and EMIs.” Tenali looked up calmly. “Then Maharaj… the problem is not profit. The problem is where the money is.” Maharaj frowned. “But sales are growing. The accounts show profit. Then […]
Maharaj said proudly, “We have a strong quality team.” Tenali smiled, “That may be the problem, Maharaj.” The room fell silent. Tenali walked through the factory. Production chasing speed. Purchase negotiating cost. Sales pushing volume. Quality inspecting finished goods. He asked, “When something goes wrong, who is blamed?” “Quality department,” Maharaj replied. Tenali asked,“And when […]
Maharaj said confidently, “Our material cost is under control. Labour is stable. Overheads are monitored.” Tenali asked, “And quality cost, Maharaj?” Silence. Tenali walked the shop floor. He saw rework tables. Rejected bins. Customer complaint emails. Urgent dispatch labels. “Maharaj,” he said, “Quality problems do not sit in one ledger. They hide.” He counted: Rework. […]
