The ~500-person workforce across the Ambernath plant, bazaar-trade sales, OEM & industrial sales, R&D and corporate functions — capacity utilization, right-first-time and skilling by team, and the capacity already paid for but sitting idle.
The workforce runs at 85% capacity utilization vs a 93% target — 8 points of already-paid capacity sitting idle, worth ~₹149 Cr of throughput with zero new lines. The idle capacity is concentrated where automation and skilling are still ramping; closing it converts straight to margin.
3 of 3 headline metrics improving vs prior · still off target: Blend First-Pass Quality 97.0% vs 99.0%, Ambernath Capacity Utilization 84.0% vs 90.0%, On-Time Dispatch 96.0% vs 98.0%
R&D / Technology (Ambernath lab) runs lowest at 80% utilization with 6 open reqs and 92% skilled — the thinnest bench and the biggest idle slice.
~8 points of idle, already-paid capacity across 500 people — running it adds ~₹149 Cr of throughput with no new lines.
The workforce is a largely fixed cost whether or not the plant and channel run full. At 85% capacity utilization vs a 93% target, several points of already-paid capacity sit idle — the single biggest operational lever after pricing, and it's concentrated where plant automation (SAP/MES) and skilling are still ramping.
Capacity utilization, right-first-time and skilling by team — the watch teams match the programs map.
| Team / function | People | Capacity util | Right-first-time | MTTR | Skilled | Open reqs |
|---|---|---|---|---|---|---|
| Ambernath — Blending, Filling & Plant | 170 | 84% | 97% | 5.2h | 86% | 14 |
| Sales & Distribution (bazaar trade) | 120 | 88% | 95% | — | 82% | 20 |
| OEM & Industrial Sales (Premium Blue / Ultramax) | 60 | 85% | 96% | — | 88% | 8 |
| Corporate / Finance / IT / HR | 60 | 82% | 97% | — | 90% | 5 |
| Supply Chain, Logistics & DCs | 50 | 86% | 96% | 6h | 84% | 7 |
| R&D / Technology (Ambernath lab) | 40 | 80% | 98% | — | 92% | 6 |
Running the idle capacity adds throughput with zero new lines.
~8 points of idle, already-paid capacity across 500 people. Closing it — better line balancing, less rework, and faster skilling onto automated lines — converts straight to margin. Pair with right-first-time (96%→99%): every avoided rework lot is pure profit.
Same teams where automation & skilling programs are still ramping.
Not a coincidence: R&D / Technology (Ambernath lab) and Corporate / Finance / IT / HR run lowest — the same teams where plant automation (SAP/MES) and skilling are still ramping. Accelerating skilling and line balancing lifts utilization and right-first-time together.