The Analytics Pro

Transforming Manufacturing & Supply Chain Operations Through Advanced Analytics

Delivered $20M+ in proven cost savings across 60+ factories worldwide

Free 20-Min Discovery Call Explore Services

About Shaju Madhavan

With over 20+ years of expertise in manufacturing analytics and supply chain optimization, I've helped businesses across industries achieve operational excellence and significant cost reductions. My proven track record includes delivering $20M+ in cumulative savings for clients across India, Sri Lanka, UAE, Singapore, and Malaysia.

I specialize in transforming traditional manufacturing and logistics operations through data-driven insights, predictive analytics, and proven frameworks. Having worked with industry leaders and top consulting firms like Bain, Deloitte, EY, and KPMG, I bring enterprise-level expertise to businesses of all sizes.

My approach combines deep technical knowledge with practical implementation, ensuring that analytics solutions deliver measurable ROI and sustainable improvements. Every project follows a 'build-operate-transfer' model, ensuring long-term value creation for my clients.

Credentials & Expertise

Education: B.E (Mechanical), EGMP (IIM Bangalore), Digital Marketing Strategy (IIM Bangalore)

Specializations: Six Sigma Black Belt, Lean Manufacturing, Supply Chain Analytics, Predictive Maintenance, Inventory Optimization

Industries: Manufacturing, Automotive, F&B, Chemical, Industrial Equipment, E-commerce, Technology

Geographic Reach: India, Sri Lanka, UAE, Singapore, Malaysia

Expert Consulting Services

📊

Manufacturing Analytics & Optimization

Transform your manufacturing operations with data-driven insights and predictive analytics.

  • Production efficiency optimization
  • Quality control analytics
  • Predictive maintenance
  • Real-time operational dashboards
  • OEE improvement strategies
🚚

Supply Chain & Logistics Optimization

End-to-end supply chain transformation for maximum efficiency and cost reduction.

  • Supply chain network design
  • Freight cost optimization
  • Logistics contracting & consulting
  • Distribution center optimization
  • Last-mile delivery solutions
📦

Inventory Management & Reduction

Strategic inventory optimization using advanced statistical models and forecasting.

  • ABC classification methodology
  • Safety stock optimization
  • Demand forecasting models
  • Min-Max inventory levels
  • Cash flow improvement
🔮

Predictive Analytics & Industry 4.0

Leverage AI/ML technologies for predictive insights and smart manufacturing.

  • Predictive maintenance systems
  • Quality prediction models
  • Demand sensing analytics
  • IoT integration & monitoring
  • Digital twin implementations
💰

Cost Reduction & Operational Excellence

Systematic approach to identify and eliminate operational inefficiencies.

  • Six Sigma methodologies
  • Lean manufacturing principles
  • Process reengineering
  • Cost analysis & benchmarking
  • Performance improvement programs
💻

Technology Implementation & Integration

Large-scale IT deployments and system integrations for manufacturing and logistics.

  • ERP system implementations
  • WMS/TMS deployments
  • Analytics platform development
  • System integration & automation
  • Digital transformation strategies

Ready to Transform Your Operations?

Book a free 20-minute consultation to discuss your specific challenges and opportunities.

Schedule Free Consultation

Free Analytics Calculators

Use these powerful calculators to estimate potential savings and optimize your operations

📦

Inventory Reduction Calculator

Calculate potential cost savings from inventory optimization and working capital improvements.

🛡️

Safety Stock Optimizer

Determine optimal safety stock levels based on demand variability and service levels.

📊

Min-Max Inventory Levels

Calculate optimal minimum and maximum inventory levels for efficient stock management.

🚚

Freight Cost Optimizer

Analyze freight costs and identify optimization opportunities for logistics savings.

⚙️

OEE Calculator

Calculate Overall Equipment Effectiveness and identify improvement opportunities.

💰

Analytics ROI Calculator

Estimate return on investment for manufacturing analytics and optimization projects.

Proven Success Stories

Food & Beverage Manufacturing

$2.6M Annual Freight Cost Reduction

Challenge:

A Major F&B Business with $400 Mn Turnover had challenges in their Logistics & Transportation operations, primarily due to inefficiencies across people, process and systems.

Solution:

Implemented strategic supply chain modeling analyzing operating windows, lead times, turnaround times, payload optimization, and vehicle type selection. Developed a comprehensive freight optimization framework.

Results:

$2.6M

Annual freight cost savings achieved through optimized logistics operations and strategic supply chain redesign.

Industrial Manufacturing

40% Inventory Reduction & Cash Flow Improvement

Challenge:

A $80 Mn Industrials business faced excessive inventory levels tying up working capital and impacting cash flow efficiency across their operations.

Solution:

Implemented comprehensive inventory modeling using ABC classification, statistical forecasting models, and sales-forecast-based optimization rather than historical data approaches.

Results:

40%

Inventory reduction achieved, with safety stock costs reduced from >6.5% to <3.5%, doubling cash flow efficiency.

E-commerce & Distribution

Rural E-commerce Scale-up: $0.2M to $4.1M MRR

Challenge:

A rural e-commerce startup needed to rapidly scale order fulfillment operations across 15 states while maintaining service quality and cost efficiency.

Solution:

Deployed 55 distribution centers in 12 months, covering 150,000+ villages with 45+ active SKUs. Implemented end-to-end supply chain optimization including last-mile delivery solutions.

Results:

2000%

MRR growth from $0.2M to $4.1M with 14% logistics cost reduction and comprehensive rural market coverage.

Latest Insights & Articles

Stay updated with the latest trends in manufacturing analytics and supply chain optimization

📊
Coming Soon

The Future of Manufacturing Analytics: AI-Driven Insights

Explore how artificial intelligence is transforming manufacturing operations and driving unprecedented efficiency gains...

Read More →
🚚
Coming Soon

Supply Chain Resilience: Lessons from Industry Leaders

Learn from real-world case studies on building resilient supply chains that can withstand disruptions...

Read More →
💰
Coming Soon

ROI-Driven Analytics: Measuring What Matters

Discover proven frameworks for implementing analytics initiatives that deliver measurable business value...

Read More →

Blog articles will be regularly updated. Subscribe to stay informed about the latest insights!

Ready to Transform Your Operations?

Schedule a free 20-minute discovery call to discuss your specific challenges and explore how analytics can drive measurable improvements in your business.

Schedule Free Discovery Call

📧 shaju@theanalyticspro.com

📱 +91 99624 48274

🔗 LinkedIn Profile