What We Thought: "Run 3 Shifts to Meet Demand"
"We need to increase production capacity by 40%. Let's run three shifts and hire more workers."
What Actually Happened:
- Bottleneck was in packaging, not production—added shifts didn't help
- Increased labor costs by ₹8 lakhs per month with no output gain
- Night shift had 23% more defects due to fatigue and poor lighting
- Still missed 18% of delivery deadlines