Transforming Gokul Tex Print:
A Journey to Operational Excellence with Stratefix Consulting
Mr. Siddharth Dhawan and Harsh Dhawan, Director of Gokul Tex Print Pvt. Ltd., proudly oversees one of India’s leading names in textiles and garment manufacturing. Since its establishment in 1993, Gokul Tex Print has become synonymous with high-quality, sustainable fabrics, serving both domestic and international markets with cutting-edge manufacturing technology.
However, as the business expanded, so did the complexity of its operations, leading to several challenges that hindered efficiency and growth.Here’s how Stratefix Consulting partnered with Gokul Tex Print to address these issues and set the company on a path to operational excellence.
Business Challenges and Gaps Identified by Stratefix
As Gokul Tex Print grew rapidly, it became increasingly difficult to manage the day-to-day operations effectively. Some of the major challenges included:
- Data Management and Visibility Issues: The company struggled with organizing and analyzing the vast amounts of production data. This lack of real-time insight led to inefficiencies and delays in fulfilling customer orders.
- Internal Team Coordination: Different departments often operated in silos, leading to poor communication, misunderstandings, and slow decision-making, which ultimately hampered production efficiency.
- Lack of Role Clarity and Accountability: While the company had experienced department heads, their roles and responsibilities were not clearly defined, leading to confusion and a lack of accountability.
- Performance Measurement Concerns: Employee evaluations were not based on clear, measurable goals, making it difficult to assess individual contributions and overall productivity.
- Inconsistent SOPs and Operational Processes: Although some standard operating procedures (SOPs) were in place, they were not consistently followed across departments, leading to variability in quality and operational inefficiencies.
- ERP Implementation Issues: The existing ERP system was misaligned with company needs, leading to inaccurate data entry and suboptimal use of the system.
- Unstructured HR Practices: The absence of structured HR policies and training programs led to unclear job roles and poor employee engagement.
- High Delivery Time Period: Undefined delivery time led to production delays, increased costs, customer dissatisfaction, supply chain disruptions and quality control issues.
Stratefix Consulting’s hands on Approach
To address these multifaceted challenges, Stratefix Consulting implemented a series of targeted interventions across various departments, ensuring alignment between people, processes, and technology.
Our Business Operation experts quickly identified the core issues and worked closely with Mr. Siddharth Dhawan and his team to develop and implement practical solutions tailored to Gokul Tex Print’s unique needs.
Data Management and Real-Time Tracking:
Stratefix implemented a robust system to capture, organize, and analyze production data in real-time.
We introduced a data tracker system that measures and highlights variances from defined standards, ensuring accountability across departments.
Key performance metrics, such as Turnaround Time (TAT), were integrated into the ERP dashboard, providing real-time visibility into production processes.
This gave Gokul Tex Print a clear view of their operations and highlighted areas for improvement.
Impact:
- 100% accuracy in data entry, allowing for real-time monitoring and quicker decision-making.
- Significant reduction in delivery delays, leading to higher customer satisfaction.
- Improved stake holder’s decision-making with real-time operational insights.
- Taking proactive decisions on alarming situations.
Enhancing Team Coordination aligned to achieve common goals:
Stratefix established regular team meetings and fostered open communication across all departments.
This initiative was crucial in resolving misunderstandings, improving coordination between the mill (manufacturing units) and internal teams, and speeding up production processes.
This fostered a more collaborative environment and improved problem-solving.
Impact:
- 20% reduction in production delays due to better coordination and faster issue resolution.
- Implementing agile project management techniques for Stronger teamwork and a more cohesive organizational culture.
Defining Roles and Responsibilities for Team Success:
Stratefix developed a RACI (Responsible, Accountable, Consulted, Informed) matrix for all departments, clearly defining roles and responsibilities.
This structure ensured that each department head and team member was fully aware of their duties, reducing role overlap and enhancing accountability. This eliminated confusion and ensured accountability.
Impact:
- 100% documentation of roles and responsibilities.
- Improved clarity and alignment within the organization leading to increased efficiency.
- Enhanced accountability among department heads, improving task execution.
Implementing a Comprehensive Performance Management System (PMS):
A robust PMS was introduced, incorporating Key Performance Indicators (KPIs) and regular performance reviews.
Stratefix ensured that 60% of the workforce was evaluated based on these newly established KPIs, shifting from subjective assessments to data-driven evaluations.
This new system was aligned with individual roles and company objectives. Monthly performance reviews were initiated, making assessments more objective and actionable.
Impact:
- 60% of employees now undergo KPI-based reviews, resulting in more accurate performance evaluations.
- Better alignment of employee efforts with company goals, boosting overall productivity.
- Improved performance tracking and employee accountability across all levels.
Developing and Implementing Standard Operating Procedures (SOPs) across all Departments:
Stratefix created and audited SOPs for all key processes, including Quality Control (QC), Scrap Management, Security, Order Samples, Inventory, and Accounts.
Regular audits were conducted to ensure compliance and consistency in operations.
Stratefix developed and enforced SOPs across all departments including all key processes, ensuring consistency and high standards in production and operations.
Impact:
- Improved operational efficiency, quality and consistency across all units.
- 20% increase in overall productivity due to streamlined processes.
- Departmental Training, Monitoring and Review systems with structured guidelines to help standardize tasks and improve efficiency.
Finding and implementing the Best Enterprise Resource Planning (ERP) System designed for Textile Industry:
Stratefix conducted an in-depth evaluation of ERP systems and selected one that best suited Gokul Tex Print’s needs. We also standardized the ERP data entry process and established regular audits to ensure data accuracy.
Additionally, Management Information System (MIS) reports were tailored to provide actionable insights, and department-specific TAT tracking was incorporated into the ERP dashboard.
Impact:
- Improved data accuracy and reliability.
- Weekly and monthly MIS reports enabled stake holders to identify gaps allowing informed decision-making.
- ERP systems providing end-to-end visibility and control for the management. This robust system now allows stakeholders to make data-driven choices in real-time, from managing completed items to tracking the flow of raw materials.
Strengthening the role of HR in Building a Positive Company Culture:
Stratefix introduced comprehensive HR policies, including leave, attendance, loan, and induction processes.
A structured training program based on a skill matrix was implemented, addressing 80% of identified skill gaps.
Impact:
- 80% of skill gaps were addressed through targeted training programs.
- 70% improvement in induction and onboarding, leading to higher employee retention and morale.
- More team building initiatives were designed to enhance employee morale creating a more efficient, safer and professional work environment.
Implementation of 5S Methodology for textile and garment industry
Regular 5S (sort, set in order, shine, standardize, and sustain the cycle) training and audits were also conducted to maintain an organized work environment.
Impact:
- Significantly reduced waste, improved production quality with cost reduction.
- Defined SOPs for regular audits across all departments.
- This also promoted overall workplace standardization and safety leading to more consistent operational results.
Key Results Achieved
The partnership with Stratefix Consulting brought about a remarkable transformation at Gokul Tex Print, driving substantial improvements across the board.
One of the key successes was the implementation of the 5S methodology, which not only organized the work environment but also instilled a culture of discipline and efficiency.
Stratefix’s meticulous documentation and regular audits ensured that these practices were not just implemented but sustained over time, creating a ripple effect of increased productivity and reduced waste across all departments.
ERP optimization was another game-changer. Stratefix carefully selected and customized an ERP system tailored to Gokul Tex Print’s specific needs, ensuring accurate data entry and real-time tracking of operations.
This system allowed for more informed decision-making, with Management Information System (MIS) reports now providing clear, actionable insights.
As a result, the overall Turnaround Time (TAT) for orders improved dramatically, dropping from an average of 60 days to now 40-45 days—a significant enhancement that directly boosted customer satisfaction and operational efficiency.
Process streamlining across all departments played a crucial role in these achievements. By clearly defining roles and responsibilities through the RACI matrix and standardizing SOPs, Stratefix eliminated confusion, improved accountability, and enhanced coordination.
This comprehensive approach not only led to a 25% increase in productivity but also positioned Gokul Tex Print for future growth, making them more agile and responsive in the fast-paced textile industry.
The on-ground support provided by Stratefix’s team, combined with their strategic know-how, has set Gokul Tex Print on a path to sustained success, showcasing the power of disciplined processes and data-driven management in achieving operational excellence.
Gokul Tex Print now enjoys:
- Faster Deliveries: Real-time data management and streamlined processes have significantly reduced delivery delays.
- Stronger Teamwork: Improved communication has fostered better collaboration and problem-solving.
- Increased Operational Efficiency: Standardized procedures and clear role definitions have led to a marked increase in productivity.
- Happier Employees: A more organized and transparent work environment has led to higher employee morale and engagement.
- Data Driven Decision Making (DDDM): Management team is now using technology driven data analytics to forecast and make critical business decisions with insights that help streamline operations, reduce waste, and improve efficiency. This is applied to every stage of the production process, from sourcing raw materials to delivering finished products.
In Conclusion
Mr. Siddharth Dhawan, Director of Gokul Tex Print Pvt. Ltd., played a pivotal role in the company’s transformation journey. His proactive involvement was crucial in implementing Stratefix Consulting’s strategies on the ground
In an industry as competitive and fast-paced as textiles, operational excellence is not just a goal – it’s a necessity.
According to a report by Technavio, the global textile market is expected to grow by USD 795.76 billion during 2023-2030, driven by increasing demand for sustainable products and innovative fabric technologies.
Mr. Dhawan was receptive to new ideas and made himself available whenever needed, ensuring smooth communication and timely decision-making. His commitment to the project’s success played a pivotal role in driving the positive changes across the organization.
As Gokul Tex Print continues to expand, they are now better equipped to meet the demands of a growing business and achieve long-term success.
For businesses to capitalize on this growth, it’s crucial to have streamlined processes, real-time data management, and a well-organized work environment.
Stratefix Consulting has proven to be a valuable partner in achieving these objectives, as evidenced by the success at Gokul Tex Print.
By embracing 5S practices, optimizing ERP systems, and standardizing operation processes, textile companies can not only enhance their operational efficiency but also set themselves up for long-term success in a competitive marketplace.
Is your textile business ready to scale new heights? Partner with us to transform your business operations and drive sustainable growth.
Contact us today to find out how we can help you achieve excellence.