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CASE STUDY — INDUSTRIAL GEARBOX

Building a Resilient India Supply Chain for a Leading European Industrial Gearbox OEM

Accelerating Time-to-Market Through Supplier Transformation, Manufacturing Excellence & Cost Competitiveness

Building a Resilient India Supply Chain for a Leading European Industrial Gearbox OEM
Industry Industrial Gearboxes & Power Transmission
Client Leading European Industrial Gearbox OEM
Business Objective Supply Chain Resilience, Cost Optimization & Faster Time-to-Market
Client Presence Established Procurement Team in India
Our Role Supplier Transformation • Manufacturing Capability Development • Engineering & Industrialization Support
Project Duration 5 Months
RESULTS AT A GLANCE

The impact in numbers.

68 Components Successfully Developed
42 Components Industrialized at Primary Supplier
3 Strategic Manufacturing Locations
3 Qualified Manufacturing Partners
5 Months Project Duration
~40% Reduction Development Lead Time
Accelerated Time-to-Market
Optimized Manufacturing Cost
01
THE CHALLENGE

Understanding the business challenge.

The client already had an established procurement organization in India responsible for sourcing and supplier management.

However, the rapid industrialization of 68 industrial gearbox components, supplier capability enhancement, cost optimization, and export readiness required specialist expertise beyond traditional procurement.

The objective was to build a resilient India supply chain capable of supporting European exports and domestic manufacturing while reducing development timelines, improving manufacturing capability, and achieving long-term cost competitiveness.

02 — OUR APPROACH

From strategy to execution.

01

Strategic Supplier Development

Working alongside the client's India procurement team, we provided specialist execution support to accelerate supplier readiness and manufacturing excellence.

  • Developed a resilient supplier ecosystem across three strategic manufacturing locations.
  • Matched component complexity with the most capable manufacturing partners.
  • Accelerated supplier qualification and industrialization.
02

Supplier Transformation

The primary supplier was transformed from a conventional machining vendor into a globally competitive manufacturing partner by supporting:

  • Precision machining capability enhancement
  • Process optimization
  • Manufacturing engineering improvements
  • Machine shop workforce upskilling and operator competency development
  • Production planning and workflow optimization
  • Quality system strengthening
  • Export manufacturing readiness
03

Engineering & Industrialization

Our team coordinated:

  • Manufacturing feasibility reviews
  • New Product Development (NPD)
  • Design for Manufacturability (DFM)
  • Engineering coordination
  • Production process development
  • Product validation
  • Industrialization and production launch
03 — TRANSFORMATION

Before → After

BEFORE AFTER
Existing procurement capability but limited supplier transformation resources
Specialist supplier development expertise integrated with the client's procurement team
Conventional machining supplier
Export-ready manufacturing partner with enhanced capability
Limited machine shop capability
Advanced machining processes and improved manufacturing efficiency
Workforce with limited exposure to global manufacturing practices
Skilled machine shop workforce trained to meet international quality and productivity standards
Longer product development cycle
68 components industrialized within 5 months
Higher development effort and fragmented execution
Integrated supplier development, engineering, and project management under one consulting partner
Single-source manufacturing dependence
Multi-location manufacturing ecosystem across 3 strategic locations
Higher manufacturing and development costs
Competitive India manufacturing platform delivering long-term cost advantages
04 — CLIENT VALUE CREATED

Value beyond sourcing.

01

Faster Time-to-Market

Successfully developed and industrialized 68 gearbox components within five months, enabling faster product launches and improved responsiveness to customer demand.

02

Supplier Transformation

Developed the selected supplier into a globally competitive manufacturing partner through:

  • Advanced machining capability development
  • Workforce skill enhancement
  • Manufacturing engineering improvements
  • Process optimization
  • Quality system strengthening
  • Export manufacturing readiness
03

Cost Competitiveness

The India sourcing strategy improved the client's overall cost position through:

  • Competitive manufacturing costs
  • Reduced product development costs
  • Lower supplier development effort
  • Improved manufacturing productivity
  • Better machine utilization
  • Reduced engineering coordination effort
  • Optimized Total Landed Cost (TLC) for European exports
04

Stronger Supply Chain Resilience

Established a diversified manufacturing ecosystem across three strategic locations, reducing supply concentration risk and improving long-term business continuity.

05

Export-Ready Manufacturing Platform

Created a scalable India supply base capable of supporting:

  • Strategic exports to Europe
  • Local manufacturing in India
  • Future product localization
  • Capacity expansion for global demand
06

Collaborative Delivery Model

By complementing the client's existing India procurement organization with specialist supplier development and industrialization expertise, we accelerated execution without increasing the client's internal resources.

05 — BUSINESS IMPACT

Measurable business outcomes.

68 industrial gearbox components successfully developed

42 precision components industrialized at a transformed manufacturing partner

Qualified manufacturing ecosystem established across 3 strategic locations

~40% reduction in development and industrialization lead time

Improved manufacturing productivity through machine shop capability enhancement and workforce skill development

Competitive India manufacturing platform delivering lower Total Landed Cost (TLC)

Export-ready supply chain established for Europe and India

Stronger supply chain resilience through multi-location sourcing and supplier transformation

Delivered specialist execution support alongside the client's existing procurement organization

CLIENT OUTCOME

From challenge to a scalable, resilient supply chain.

Within just five months, we transformed a conventional supplier development initiative into a strategic manufacturing capability program.

By combining supplier transformation, machine shop workforce development, engineering support, manufacturing excellence, and strategic sourcing, we enabled the client to industrialize 68 gearbox components, establish an export-ready supply chain, improve cost competitiveness, accelerate time-to-market, and build a resilient manufacturing ecosystem supporting both European exports and future growth in India.

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