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 structured system.” Maharaj answered quietly.
Tenali leaned forward.
“Here’s your leakage:
- Target clarity at worker level: 0%
- Communication delay: 1–2 days
- Repeated errors: ~18% of output
- Supervisor dependency: 100%
Your problem is not production. It’s communication flow.”
Maharaj looked surprised.
“So what’s the fix?”
Tenali replied, “Three simple controls;
- Daily production huddle.
- Visual performance boards.
- And a feedback loop.”
This is basic Throughput Thinking.
If information flow is blocked, output flow collapses.”
Within a month, output reached 480 units.
Maharaj smiled.
“Tenali… we didn’t increase capacity.”
Tenali nodded.
“Yes Maharaj… You removed confusion.”