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Empowering Scalable Growth in FMCG and Manufacturing
The global FMCG market surpassed $11 trillion in 2024 (Fortune Business Insights), with manufacturing contributing over 16% of global GDP (World Bank, 2024). End-to-end consulting to drive efficiency, innovation, and resilience across fast-moving consumer goods and industrial production ecosystems.
Manufacturing & FMCG Overview & Market Trends
Smart Manufacturing
Agile Production Planning
Agile Production Planning
Utilizes IoT, robotics, and digital twins to improve productivity, reduce waste, and enable real-time monitoring.
Agile Production Planning
Agile Production Planning
Agile Production Planning
Supports SKU diversification and quick changeovers using S&OP tools and demand-driven scheduling.
ESG-Driven Operations
Data-Driven Demand Forecasting
Data-Driven Demand Forecasting
Aligns production with environmental goals and regulatory frameworks through energy efficiency and sustainable sourcing
Data-Driven Demand Forecasting
Data-Driven Demand Forecasting
Data-Driven Demand Forecasting
Leverages AI and POS data to improve forecast accuracy and optimize service levels.
Top Manufacturing & FMCG Industry Challenges
Inefficient production lines
Inefficient production lines
Inefficient production lines
We apply lean layouts and automation to reduce bottlenecks and increase throughput.
Poor forecast accuracy
Inefficient production lines
Inefficient production lines
We build predictive models that align supply with true demand across regions.
Limited business visibility
Inefficient production lines
Limited business visibility
We implement planning tools that align sales, inventory, and procurement data.
Lack of pricing strategy
Inefficient production lines
Limited business visibility
We analyze cost structures and market positioning to guide pricing decisions.
Our top Our Capabilities in FMCG & Manufacturing
Production Efficiency & OEE Improvement
Boost asset utilization and minimize unplanned downtime using lean and TPM frameworks.
SKU Rationalization & Product Portfolio Strategy
Reduce complexity, improve margins, and align portfolio with consumer demand.
End-to-End Supply Chain Diagnostics
Identify hidden inefficiencies in procurement, warehousing, and logistics.
Factory Automation & Industry 4.0 Deployment
Implement smart sensors, data capture systems, and robotics for scalable automation.
Cost-to-Serve & Profitability Modelling
Uncover high-cost products, channels, and markets to guide pricing and operational focus.
Industry 4.01 FMCG and Manufacturing Case study
23 M EGP restored in less than 90 days in a turnaround engagemen
In Egypt and at the premises of one of the top manufacturers of shoes and garments where Industry4.01 was engaged for a turnaround, The client faced an issue due to defected 45,000 pair of shoes that has been spread in the market and nearly damaged his reputation which leaded to have key accounts holding the payment to the business, Multiple frauds and red-flags were determined, a damage control plan initiated with the focus to collect damaged products and restore reputation, New production lines introduced, recalling all old products and has been recycled and clients substituted with new high grade products, after a long negotiation with key brands around 23 M EGP were collected from credit notes which enabled the client to restore industrial activities afterwards
Get a Free Strategy Session with Our FMCG and Manufacturing
Speak with a FMCG and Manufacturing industry expert
Struggling with margin pressures, complexity, or outdated operations?
Let our team help you transform your FMCG or manufacturing business.
Meet our FMCG and Manufacturing consultants
Alaa Mahmoud
Alaa Mahmoud
Alaa Mahmoud
PhD , PMP, CLLSSBB Bachelor in in Engineering with more than 15 years of quality, engineering, manufacturing and hands on experience in ISO, certification, Lean, Total quality management , Alaa has extensive experience upgrading multiple factories in ATM smart cards, Automotive ,Telecommunication and electronics
Yehia Murad
Alaa Mahmoud
Alaa Mahmoud
PMP, CL GSSBB As an experienced 20+ years Ex Nestltle, Pepsico in Egypt, middle east and other multinationals with extensive experience in continuous improvement, 5S, lean Kaikau, PMP, Agile with extensive hands on in production, quality, people management and lean tools