The plant & shop-floor workforce — capacity utilization, right-first-time and skilling by cluster, and the capacity already paid for but sitting idle.
The workforce runs at 83% capacity utilization vs a 90% target — 7 points of already-paid capacity sitting idle, worth ~₹215 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: First-Pass Quality Yield 96.5% vs 99.0%, Plant Capacity Utilization 82.0% vs 90.0%, On-Shelf Availability 92.0% vs 96.0%
Franchise bottling & co-packing runs lowest at 80% utilization with 60 open reqs and 80% skilled — the thinnest bench and the biggest idle slice.
~7 points of idle, already-paid capacity across 5,500 operators — running it adds ~₹215 Cr of throughput with no new lines.
The workforce is a largely fixed cost whether or not the lines run full. At 83% capacity utilization vs a 90% 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 cluster — the watch clusters match the transformation map.
| Plant cluster | Operators | Capacity util | Right-first-time | MTTR | Skilled | Open reqs |
|---|---|---|---|---|---|---|
| Manufacturing — owned plants & lines | 2,600 | 82% | 96% | 6h | 84% | 140 |
| Sales & Distribution (GT · MT · Q-comm) | 1,200 | 85% | 96% | — | 86% | 90 |
| Franchise bottling & co-packing | 600 | 80% | 94% | 6.5h | 80% | 60 |
| Supply chain & logistics | 400 | 84% | 95% | — | 82% | 40 |
| Corporate · Finance · IT · HR | 400 | 84% | 97% | — | 88% | 20 |
| Marketing · R&D · New Products | 300 | 84% | 98% | — | 90% | 30 |
Running the idle capacity adds throughput with zero new lines.
~7 points of idle, already-paid capacity across 5,500 operators. 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 clusters where automation & skilling programs are still ramping.
Not a coincidence: Franchise bottling & co-packing and Manufacturing — owned plants & lines run lowest — the same clusters where plant automation (SAP/MES) and operator skilling are still ramping. Accelerating skilling and line balancing lifts utilization and right-first-time together.