For foundries and engineering job shops

You know every total. Do you know any single part?

In three weeks, see where your money goes: metal, power, customers and cash. Then find out which of your parts earn and which ones quietly lose.

Book a Margin and Capacity AuditSee how it works

Nothing changes on your shop floor. Fixed scope. Fixed fee. Three weeks.

The average always works out. That is the trap.

You can tell anyone, to the rupee, what you sold last year, what you spent on scrap and pig iron, what the power bill was and what you paid in wages. It is all in Tally, and it is correct.

But there are things Tally cannot tell you:

  • How those totals split across your 60 part numbers and your 12 customers.
  • Which parts earn well, and which ones are paid for by the good ones.
  • How much of the metal you buy actually leaves the gate and gets paid for.
  • Whether your biggest customer, the one you have served for years, is really making you money.

So you price on a rough rate per kg, and hope the average works out. It does. The average looks comfortable while some parts lose money behind it. You are busy all year, turnover is up, and there is no money in the bank, and you genuinely do not know why.

You are not replacing your Tally. You are answering the one question it cannot answer.

The Margin and Capacity Audit

A three-week study of your own records. It needs no new forms and no change on the shop floor.

Know your true yield

See how much of every 100 kg of metal you buy actually leaves your gate and gets paid for. Very few owners know this number. When it is lower than expected, the missing kilos are real money.

Know your power number

See the units of electricity you use per tonne of good castings, and where you stand against the usual range for Kolhapur foundries. See also what your bill hides: maximum demand, power factor, load factor and time-of-day use.

Rank your customers by what they earn you

See what each customer really brings you per kg after metal and conversion cost. See how much of your sales depends on one or two customers.

See where your cash is stuck

See how many days each customer takes to pay you, how many days you take to pay, and how long your cash is tied up in the cycle.

Start from a page you sign

Your last 12 months become a one-page Opening Position that you approve. Every later report is compared with it, so there is nothing to argue about.

Your records needed: Tally data, 12 months of electricity bills, 12 months of GST returns and dispatch tonnage. That is all.

Book a Margin and Capacity Audit

From totals, to parts, to quotes

You do not need everything on day one. You start with the audit. The rest is added step by step, as your team gets comfortable.

  1. Find out where the money goes

    The Margin and Capacity Audit gives you your true yield, your power number, your customers ranked by what they earn and your cash cycle. It shows the plant average and your customers. It does not yet show each part.

    When: three weeks

    What changes on the shop floor: nothing

  2. Find out which parts earn and which lose

    One daily record is added: what was poured and what was rejected, by part number. Many foundries already keep a pouring or inspection register on paper, so the job is to give it a fixed shape, not to create new work. Then your report can look like this:

    Example only — numbers are for illustration:

    "Of your 58 parts, 19 lose money. They are 22% of your sales and take 31% of your moulding line time. Two of them belong to your biggest customer."

    Rejection also shows in rupees, not just percent. A 9% rejection rate sounds tolerable. The same number written as lakhs a year does not.

    When: from the second to fourth month

  3. Quote with a price you can defend

    Coming soon

    Once the real cost of each part is known, you can quote each new enquiry with a known floor price instead of a rough rate per kg. You enter the weight, grade, line and quantity, and you see the lowest price that still pays.

    When: after Stage 2 is running.

Later, you can also find the hours that are hiding in your plant: breakdowns, changeovers and waiting time. Sometimes a plant that thinks it needs a second furnace needs more hours from the one it has.

The quickest win is often in your electricity bill

Your bill hides money in the way you use power, not just how much you use. Maximum demand against contract demand, power factor, load factor and the time of day you run the furnace all change what you pay.

  • You see how your plant uses power, in plain numbers.
  • You see what each of those is costing you.
  • You get a short list of changes to make. Power fixes are often the quickest to show up, sometimes within a billing cycle or two.

You also see your units per tonne of good castings. A study for SIDBI found that Kolhapur foundries typically use roughly 1,000 to 1,200 units per tonne, with melting taking the biggest share. You can see where your plant stands against that range.

Get your cash back in your hands

Many foundries wait 100 days or more for payment from customers, but pay their own suppliers in 30. That gap is why a busy plant can be short of cash.

  • You see, customer by customer, who is paying late.
  • You see where the rules on payment to small suppliers are on your side.
  • You see whether early-payment platforms like TReDS could release cash that is stuck in invoices.

This is cash that already belongs to you.

Your numbers will not clash with your audited accounts

Costing figures always differ a little from audited accounts, because stock, depreciation and timing are treated differently. You get a one-page reconciliation that lists every difference and why. It is shared with you and your CA before anyone has to ask.

  • This is not an audit. Your profit is never restated.
  • Your Tally is never changed, and your GST is never touched.
  • Your CA is welcome in the meeting. Many owners find their CA is glad to see the numbers.

Your costing stays yours, even where everyone knows everyone

A signed promise

A confidentiality agreement is signed by the company before you share anything.

Only named people see your figures

Not a pool of staff. Named people only.

Never in another client's report

No client's figures appear in another client's report, even without names, unless that client gives written permission.

Benchmarks only as ranges

When enough plants have joined, you will be able to compare your yield, power per tonne and payment days with ranges from your own cluster. They are shown only as ranges across at least five plants, never as one plant's figures.

A clear rule on competing clients

Satej Consultech will not hold live costing for two clients bidding for the same part family from the same customer. If that happens, both are told, and one of them decides whether to continue.

You see it first. Alone.

Some findings are not easy to hear. Maybe a customer you have served for 14 years is not paying you what the work costs. You see every finding first, alone, in your own office. You decide who else sees it.

You are shown what a part would need to earn, with options for pricing it, not a verdict on what went wrong.

Your supervisor gets an hour back

In the first weeks, the daily production summary your supervisor writes by hand for you is prepared for him instead. He is no longer called into the office to explain figures.

For the first three months, rejection is shown by part and by reason, never by operator or shift in-charge. That is what makes this feel like a tool, not like someone watching him.

Where the growth is

Moving from raw castings to machined parts, and clearing IATF or ISO audits, opens the door to better-paying customers. That is how many plants move from around ₹8 crore to ₹20 crore. Your numbers show whether you can afford that step yet, and what to clean up first.

Talk to Us

Who gets the most from this

Works best for you if…

  • You run a foundry or engineering firm in the Kolhapur–Belgaum belt, with a team of about 30 to 200 people.
  • Something is changing: the next generation is joining, you have a large order you cannot fulfil, you have lost a big customer, you are moving from job work to your own product or to export, or a bank has said no.
  • You are ready to look at your real numbers.

May not be the right fit if…

You want to know only the price before the method, you are not ready to share your numbers, or you want a guaranteed saving. You will get an honest answer, and no hard feelings.

Three ways to work together

Margin and Capacity Audit

Three weeks, fixed scope, fixed fee. You get your Opening Position, your report and a meeting to go through it.

Monthly Growth Plans

Weekly and monthly reports, part-by-part costing, and hands-on help with marketing, finance, training or systems.

Growth Partner

For a small number of businesses that want close, weekly support, and a seat at a quarterly review of what the numbers mean.

The audit is a fixed fee, quoted after a short call. Monthly plans start from ₹15,000 a month.

Questions owners ask

A foundry finds out by working out the cost of each part, including metal, melting, moulding, rejection and power, and comparing it with the selling rate. Satej Consultech does this in two stages: a three-week Margin and Capacity Audit from Tally, power bills and GST returns, then part-by-part costing from a daily production and rejection record.

The Margin and Capacity Audit is a fixed-scope, fixed-fee, three-week study of a foundry's or engineering firm's Tally accounts, electricity bills, GST returns and dispatch tonnage. It shows overall yield, power units per tonne, margin by customer and cash tied up. Nothing changes on the shop floor.

No. Tally stays exactly as it is, and Satej Consultech only reads from it. The audit needs no new forms or registers.

Your Tally data, 12 months of electricity bills, 12 months of GST returns and dispatch tonnage. Most owners can hand these over through their accountant.

They will be close but not identical, because costing treats stock, depreciation and timing differently from audited accounts. You get a one-page reconciliation that lists every difference and why, so you and your CA can see it.

No. Costing, customers and margins are never shown to another client, and benchmarks are shown only as ranges across at least five plants. Satej Consultech will not hold live costing for two clients bidding for the same part family from the same customer.

The audit takes three weeks. Part-by-part costing usually begins in the second to fourth month, once the daily production record is running.

The audit is a fixed fee, quoted after a short call. Monthly growth plans start from ₹15,000 a month.

No. Satej Consultech does not collect any loan or investment money. It works on your costing, cash cycle and records so that banks see you as a better borrower.

A study for SIDBI found that Kolhapur foundries typically use roughly 1,000 to 1,200 units of electricity per tonne of good castings, with melting taking the biggest share. The Margin and Capacity Audit shows where your plant stands against that range.

Find out where your money really goes.

Give us one meeting. You will be asked a few simple questions about your plant. Whether or not you work with us afterwards, you will leave knowing something new about where you stand.

Book a Margin and Capacity Audit

Call or WhatsApp: +91 96075 50313 · info@satejconsultech.in

Contact Us

Office

Gala No. 219, Keviz Plaza, Venus Corner, Station Road, Shahupuri, Kolhapur, Maharashtra 416001

Call or WhatsApp

+91 96075 50313

Email

info@satejconsultech.in