Business Process Mapping and Audit for a Rubber Products Manufacturing Group

 

CLIENT CONTEXT & PROBLEM

A diversified manufacturing group with seven independently operating entities sought to bring standardization, visibility, and process discipline across its core functions—Finance, Human Resources, Procurement, Administration, and Production. The group had grown organically, and leadership observed inefficiencies, inconsistent practices, and limited coordination across units.

The objective was to conduct a comprehensive process audit to document current practices (AS-IS), identify operational gaps, and recommend improvement opportunities that could drive efficiency, cost control, and better coordination across functions.

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APPROACH & SOLUTION

• Our consulting team undertook a 3-month engagement, conducting a detailed AS-IS process study across all entities of the group. The methodology involved stakeholder interviews, workflow mapping, document analysis, and cross-functional assessments to uncover inefficiencies, bottlenecks, and best practices.

 

SOLUTION HIGHLIGHTS

Finance

• Mapped budgeting and cash flow management practices

• Reviewed accounts receivable/payable cycles and identified delays and duplications

• Assessed financial reporting frequency and format across units

• Identified the need for unified cost control parameters across entities

Human Resources

• Assessed recruitment, onboarding, and appraisal frameworks across all entities

• Identified inconsistencies in statutory compliance and payroll processing

• Reviewed employee engagement models and HR record-keeping

• Recommended uniform HR policy deployment across all entities

Procurement

• Documented vendor management and purchase order processes

• Identified lack of integration between procurement planning and inventory tracking

• Highlighted gaps in material requirement planning and cost tracking

• Recommended controls for pricing consistency and vendor evaluation

Administration

• Assessed documentation standards and inter-department communication

• Noted missing SOPs for inter-entity coordination and shared services

• Recommended centralized documentation practices for record access and transparency

Production

• Mapped production planning and scheduling processes across all units

• Studied workflows for raw material inwarding, processing, and finished goods movement

• Evaluated machinery utilization metrics and maintenance routines

• Recommended actionable improvements to enhance production efficiency and reporting

KEY DELIVERABLES

• 25+ detailed AS-IS process maps across 5 departments and 7 companies

• Gap analysis reports for each function with issue-priority grids

• Function-wise recommendation sheets with practical improvement actions

• Consolidated summary report with cross-functional insights and roadmap for process alignment

• Review workshop with top management for final handover and strategic planning

 

BUSINESS RESULTS

• Process Clarity - Unified documentation of workflows across all entities

• Operational Gaps - Identified 40+ critical gaps and inefficiencies

• Functional Alignment - Recommended steps to integrate HR, finance, and procurement

• Decision Support - Provided leadership with actionable process insights

By enabling leadership with detailed, function-wise visibility and actionable recommendations, our engagement laid the foundation for standardized operations, better cross-entity coordination, and data-driven planning. This helped set the stage for future digital transformation, internal control strengthening, and scalable growth.

If your organization operates multiple units with decentralized operations, our structured process audit and mapping services can bring clarity and cohesion to your workflows, positioning you for confident scaling and performance improvement.