Optima Margin & Operations Solutions
Defend your margins.
Production cost economics advisory for manufacturers. We trace every kilogram, kilowatt and idle-hour to your P&L, then turn it into margin you can bank, without trading away quality, safety or compliance.
38
years
running and transforming process plants
11
global sites
replicated benchmarks set under Neeraj's plant leadership
1
greenfield plant
commissioned from first drawing to rated capacity
30
days
to a fact-based diagnostic of where margin is leaking
The new mandate
From top-line expansion to margin defence.
Rising inflation, volatile input materials and competitive pressure mean manufacturers can no longer grow their way to profitability. The margin has to be engineered out of production economics.
Our goal is to unlock the efficiencies already sitting in your operations, without compromising product quality, throughput, worker safety or environmental compliance.
Production cost economics
One economic lens across your entire value chain
We link the drivers on your shop floor directly to your P&L and balance sheet, so every improvement is visible where it counts.
Material & direct inputs
Raw material yields, scrap rates, bill-of-materials variance, raw material purity, supplier pricing index and inbound freight logistics.
Assets & overheads (OEE)
Overall Equipment Effectiveness, maintenance downtime, energy per unit, facility space utilisation, and indirect selling and administrative overheads.
Labour & workforce
Direct versus indirect headcount, shift utilisation, overtime spend ratios, labour productivity metrics and skill-mix alignment.
Operational levers
Where the margin hides
We start with the levers that release cash fastest and need the least capital.
Downtime reduction (TPM)
Total Productive Maintenance frameworks that curb unplanned equipment failures and speed up changeovers.
Cycle time optimisation
Remove micro-stoppages and bottlenecks across sequential process stages to lift overall line throughput.
Yield & scrap minimisation
Find the root causes of process defects to cut rework loops, raw material waste and lost machine hours.
Energy & utility efficiency
Audit power loads during peak intervals and optimise idle-state consumption across high-draw machinery.
Margin potential estimator
What is a few percent worth on your cost base?
Adjust your cost structure and the improvement you'd expect in each area. Small gains on a large cost base add up quickly.
Materials & direct inputs
Yield, scrap, BOM variance, sourcing
Energy & utilities
Peak loads, idle-state consumption
Labour & workforce
Shift utilisation, overtime, skill mix
Maintenance & overheads
OEE, downtime, changeovers
Indicative annual savings
₹8 Cr
≈ 2.5 pts of EBITDA margin
The default figures are illustrative, not a forecast. Your real potential is set against engineering baselines in a 30-day diagnostic sprint.
Talk to us about your plantHow an engagement runs
From diagnosis to measurable value in 24 weeks
We prove savings on a pilot line before scaling, so you only scale what works.
Phase 1 · Weeks 1–4
Diagnostic
Data gathering, site tours, baseline cost modelling and joint hypothesis-building with your plant managers.
Phase 2 · Weeks 5–8
Pilot design
Proof-of-concept on a designated pilot line to validate savings and refine the execution templates.
Phase 3 · Weeks 9–24
Scale & monitor
Enterprise-wide rollout backed by a digital savings tracker for accountability and continuous KPI tracking.
Founder
“Every plant has its own set-up, controls and pain points. Lasting savings come from building the programme around them, not from importing someone else's playbook.”
Neeraj Arora
Founder & principal consultant
Close to four decades running and transforming process plants, from greenfield commissioning at the Aditya Birla Group to plant head at an Evonik group company and Vice President, Center of Expertise at Grasim Pulp & Fibre.
Talk to us
Ready to capture your margin potential?
A short conversation about your plant is the best place to start. Reach out directly, whichever way suits you.