Cost Reduction

Core Philosophy & Vision

At PBOPlus, our cost reduction philosophy is rooted in eliminating inefficiencies, not people. We believe that sustainable savings come from restructuring work, not just trimming headcount. Our vision is to create lean, agile, and future-ready operations by removing non-value-adding activities, automating the routine, and empowering multiskilled teams. With a data-driven, diagnostic-led approach, we turn everyday operations into efficient engines of productivity and cost control.

PBOPlus 7-Step Framework

for Manpower & Inventory Cost Reduction

1-month diagnostic to map utilization, workflows & manpower deployment

Identify inefficiencies in both blue-collar & white-collar operations

01: Conduct Diagnostic & Baseline Assessment

Rationalize manpower based on value-added tasks, not exception handling

Remove ad-hoc inventory trips and unjustified buffer deployment

02: Eliminate Excess & Unscientific Deployment

Introduce low-cost automation for routine/manual work in quality, data, and material flow

Free up manpower for core activities

03: Automate Repetitive & Low-Skill Tasks

Define clear role boundaries between managerial, supervisory, and operational staff

Eliminate middle-management redundancy and duplicate reporting layers

04: Redesign Roles & Reduce Overlap

Enable flexibility by training teams in multiskilling and data collection

Improve responsiveness and reduce idle labor across shifts

05: Deploy Multiskilled 3-Layer Team Structure

Standardize and digitize inventory processes, store logs & material requests

Reduce searching, rework, and manual part tracking

06: Digitize Workflows & Inventory Handling

Run performance reviews at project + level-wise cadence

Ensure constraints are escalated and internal teams are ready for takeover post-handover

07: Review Daily–Weekly–Monthly to Sustain Gains

PBOPlus 7-Step Framework

for OEE Improvement & Changeover Time Reduction

Create clear Tool–Time–Task SOPs for machine operations and changeovers

Ensure “Right First Time” execution with preparatory checks

01: Design & Deploy 3T SOPs

Use templates and checklists to monitor adherence and performance

Enable auditability and operator accountability

02

Form reliability teams for proactive machine upkeep

Reduce breakdowns through structured maintenance protocols

03: Build Preventive Maintenance Capability

Conduct speed trials and test alternative parts for faster output

Minimize setup/changeover time with process fine-tuning

04: Optimize Machine Speed & Setup

Eliminate manual, repetitive work in material movement

Improve safety and throughput with simple automation

05: Apply Low Cost Automation (LCA)

Introduce 3-layered structure with multiskilled teams

Match manpower with workload using workload analysis

06: Re-Engineer Workforce & Roles

Apply 5S and space optimization

Clear clutter, reduce search time, and smoothen man-material flow

07: Enable Flow & Eliminate Waste

PBOPlus 7-Step Model

for Manpower & Inventory Cost Reduction

Conduct Diagnostic & Baseline Assessment

1-month diagnostic to map utilization, workflows & manpower deployment.

Identify inefficiencies in both blue-collar & white-collar operations

1

Eliminate Excess & Unscientific Deployment