A 2023 capital proposal sought ₹12 crore for assembly automation. Its demonstration used a standard chair configuration and showed an orderly sequence that appealed to both production and finance colleagues. The proposal treated that sequence as representative of the business's work. Before taking it forward, I asked for a review of the configurations in a defined sample of 2,400 customer orders.
The sample contained 1,440 standard orders and 960 configured orders. The latter required combinations of components and assembly steps that the proposed sequence did not fully handle. The issue was not that automation was inherently unsuitable; it was that the investment account had not made the remaining work and its resources explicit. The production sponsor argued that the standard volume justified proceeding, while assembly supervisors wanted the configured work assessed before their teams inherited it around the new line.
With Maya and the operating leaders, we revised the question for the board. Instead of seeking approval for the original machine-led scheme, we proposed ₹4.2 crore for fixtures and training addressing a wider range of configurations. The board approved that programme. We accepted that it would not provide the same standard-model automation and kept the original proposal outside the approved capital plan.
The fixtures and training programme was completed in 2024. We did not describe the ₹7.8 crore difference between the two proposals as a realised saving: one programme had not been bought at a discount, and the scopes were different. Nor did we attach a productivity or clinical-outcome improvement without a suitable measured basis. The decision purchased a particular capability and left other possibilities open for a later investment case.
The value of the review was to make our order mix part of the capital discussion. A model can be common without representing every important demand on the factory. As CEO, I needed the board to see what each proposal would accomplish, what it would leave unresolved and why we were choosing that combination of capability, cost and limitation.