Case studies

Selected engagements.

Client identities are anonymised under engagement NDA. Sector, geography, and outcome figures are reported as the client confirmed them post-engagement.

Consumer electronics assembly

Batam, Indonesia

10-week scoped diagnostic + 90-day implementation support

Line changeover cut from 48 to 29 minutes

A Batam-based contract assembler producing small-format consumer electronics was losing 9–11 hours per week to changeovers between product variants. We ran a four-week diagnostic across two lines, observed 22 changeovers, and identified three root causes — tool set-up sequencing, operator batch handover, and a quality-check step that could be run in parallel rather than serial. The client implemented 7 of 9 recommendations over the following quarter. Measured changeover time fell from a mean of 48 minutes to 29.

Food processing

Surabaya, Indonesia

14-week scoped quality system build

ISO 22000 certification achieved at first audit

A family-owned speciality food producer in East Java with IDR 180 billion annual revenue needed ISO 22000 to unlock a national retail account and a first export contract. We delivered a 14-week engagement covering gap assessment, quality system build, SOP authoring, internal auditor training, and pre-audit review. The certification audit was passed with two minor non-conformances, both closed within 30 days. The retail account went live six months after engagement start.

Flexible packaging

Jakarta / Bekasi, Indonesia

8-week scoped supply chain review

Supplier base consolidated from 41 to 17; lead time down 22%

A specialist flexible-packaging converter serving FMCG clients across Jakarta and Bekasi was sourcing from 41 active tier-1 suppliers spread across five countries. We ran an eight-week supply chain review, modelled supplier consolidation scenarios against volume and currency assumptions, and recommended a phased move to 17 suppliers. After 12 months the client reported a 22% reduction in average lead time, a 4.3% reduction in landed cost, and a substantially simplified weekly planning cycle.

Speciality chemicals

Ho Chi Minh City, Vietnam

Express Advisory — Clinic call

Clinic call sanity-checked an $800K capex decision

A speciality chemicals operator planning an $800K reactor upgrade wanted a second opinion before board approval. A 30-minute clinic call reviewed the capex justification, challenged two of the stated process-bottleneck assumptions, and discussed alternative debottlenecking approaches. Written notes followed within a working day. The client proceeded with the capex — which was validated as the right decision — but accelerated the commissioning sequence by three months based on advice from the call.

Textiles and garment

Bandung, Indonesia

Express Advisory — Focused session + written memo

Focused session unblocked a stuck customer quality audit

A Bandung-based textile and finished-garment manufacturer three weeks from a customer-mandated quality audit had lost confidence in a prior external consultant and needed a single working session to triage documentation gaps. A 60-minute focused session reviewed their quality manual, identified the three most serious gaps, and produced a 10-day remediation plan. A written memo followed the same day. The audit was passed with two minor non-conformances closed during the audit itself.

Contract food manufacturing

Manila, Philippines

16-week scoped quality system build + validation supervision

GMP-aligned audit prep for export customer

A Metro Manila contract food producer preparing for a first customer audit from a Japanese buyer needed rapid quality-system review and documentation clean-up. Over sixteen weeks we designed the quality system, authored SOPs and work instructions, ran operator training, and supervised two validation runs. The customer’s supplier qualification audit was passed without critical findings.

Palm-oil processing equipment

Medan, Indonesia

Express Advisory — Half-day diagnostic

Half-day diagnostic prevented a $1.2M capex misstep

A North Sumatran processor considering a $1.2M capex investment in a new refining line asked for a diagnostic before committing. We spent four hours on site, interviewed six production leads, and reviewed 18 months of throughput data. The report that followed recommended capacity unlock through maintenance cadence and scheduling changes ahead of capex. The client paused the investment, implemented the recommendations, and hit their volume target without new spend.

Cosmetics contract manufacturing

Denpasar, Bali, Indonesia

Express Advisory — Written query, 24-hour turnaround

Written query clarified BPOM pathway for a new SKU range

A Bali-based cosmetics contract manufacturer preparing to launch a new natural-ingredient skincare range wanted a written second opinion on BPOM notification pathway selection, halal certification options, and stability-testing requirements before committing to the production schedule. One written query, returned within 24 hours, laid out the regulatory route, flagged two ingredient sourcing risks, and recommended a testing-laboratory combination that halved the quoted timeline.

Garment manufacturing

Semarang, Indonesia

Express Advisory — Half-day diagnostic

Half-day diagnostic deferred a second-factory commitment

A Semarang garment manufacturer sixty days from committing to a second factory building wanted an independent view on whether existing-site debottlenecking could unlock the required capacity first. A half-day diagnostic on the flagship line produced recommendations that, if implemented, would unlock an estimated 22% more throughput from the current building. The client paused the second-site decision pending a six-month implementation run.

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