Module 1 Know your customer and market 4 hAnalyse
Every sound business in manufacturing business begins with one clear customer and one clear problem. In São Paulo and the wider state, demand is real but crowded, so a small, well-described customer group wins before a broad one.
- In manufacturing business: Know buyer specs, volumes and delivery windows.
- Write the customer in one sentence: a trade buyer. Add the place, the moment of need and what they use today.
- List five rivals or substitutes within reach. For each, record price, strength, weakness and how people reach it.
- Interview at least eight real customers with open questions. Record exact words, not your summary.
- Count the market in units: how many batches could one area buy in a month? Use two public sources and your own count, then take the lower figure.
- Choose one first segment and say why the others wait.
Worked example. Weak: 'Everyone needs a made product in a steady process.' Strong: 'Our first customer is a trade buyer within 8 km of the centre, who today pays R$ 9.900 per batch and complains about delay. We target 18 batches a month by month three.'
Second worked scenario. Scenario: ten customers are interviewed for manufacturing business. Seven say price, two say speed, one says trust. Question: which first message do you write, and which interview record backs it? Model answer: lead with the batch price and speed promise, keep trust proof as the second line, and cite the seven price answers by date.
Activity. Write the one-sentence customer, a five-row rival table and eight interview records. Share them with a peer for a challenge round.
Standard to meet. Define a specific customer, build a rival table with prices, and trace every claim to an interview or a source.
Module 2 Rules, registration and data duties in Brazil 4 hUnderstand
Brazil asks every trader to be visible and accountable. Know which register, tax regime and sector rules apply before the first sale, and check each against the current official text.
- In manufacturing business: Factory licences, fire, environment and labour rules; certification where products are regulated.
- Choose a legal form: micro-entrepreneur (MEI) only if your activity appears on the official MEI list, or a company registered with a CNPJ. Regulated activities need their sector authorisation first. Check the current limits and lists on the official portal.
- Learn the tax regime that fits your size and write down which taxes you will collect and pay, and when.
- Find the sector rules for manufacturing business: licences, inspections, professional registers. List each with the office that issues it and the renewal date.
- Personal data of customers falls under Brazil's data protection law (LGPD). Collect only what you need, say why, keep it safe, and name who answers questions.
- Consumer law gives buyers clear rights on information, returns and complaints. Put your terms in plain Portuguese.
Worked example. Checklist for a new manufacturing business trader: 1) legal form (CNPJ, or MEI only if your activity is on the official list); 2) city operating licence; 3) sector licence or register; 4) tax set-up; 5) privacy notice; 6) written terms. Each has an owner and a date.
Second worked scenario. Scenario: a neighbour says registration can wait until the first R$ 45.000 of sales. Question: what do you do? Model answer: do not delay; write the compliance table first, confirm the register, tax and sector licence with the official office, and start only where the table shows no open blocker.
Activity. Build your own six-line compliance table for your first location. Mark what is done, what is pending and who confirms it.
Standard to meet. Cite an official source for every line, assume nothing, and date every pending item. Local law always wins over this course.
Module 3 Design the offer 4 hCreate
An offer states what the customer gets, how well, by when and at what price. For a made product in a steady process, the offer must make the quality visible and the next step easy.
- In manufacturing business: Offer a specified product with tolerance, lead time and warranty.
- Describe the core offer in three lines: what is delivered (a made product in a steady process), the standard it meets, and the time it takes.
- Add one proof for each promise: a sample, a test result, a guarantee or a customer record.
- Price from cost upward and from customer value downward, then pick a price inside both.
- Write a simple one-page terms sheet: what is included, what is extra, how to cancel.
- Create two options at most, so choice stays easy.
Worked example. Offer: 'A made product in a steady process, delivered within agreed time, checked against a written standard, price R$ 9.000 per batch. Proof: a dated record the customer can check and sign. Changes or cancellation by written agreement before work begins.'
Second worked scenario. Scenario: a customer asks for a discount from R$ 9.000 to R$ 8.100 per batch. Question: decide with numbers. Model answer: contribution falls from R$ 2.800 to R$ 1.900 per batch; offer an extra of value (for example faster service) before cutting price, and accept only if the lower contribution still clears break-even.
Longer notes. Choose one product you can make in repeatable batches, such as packaged sauces, and set a standard batch size. Cost a batch from raw materials, packaging, direct labour, energy and water. Compare your price with similar products on shelves and with an imported alternative. Test a pilot batch and keep the sample. Confirm factory registration, label content and product-safety rules before you sell the first pallet. Ask two buyers to test the pilot batch and give written comments on quality, packaging and delivery time. Small adjustments before launch cost far less than a recall or a returned order after the first shipment.
Extra worked example. One batch is sold for R$ 9.000. Variable cost is R$ 3.900 for raw materials, R$ 900 for packaging, R$ 1.000 for direct labour and R$ 400 for energy and water, so R$ 3.900 + R$ 900 + R$ 1.000 + R$ 400 = R$ 6.200. Margin is R$ 2.800, or 31,1 percent. Fixed cost is R$ 45.000 a month, so break-even is 45.000 / 2.800 = 16,07, rounded up to 17 batches. Take the cost items as worked-example assumptions, not market data. Thirty sauce batches leave R$ 39.000 after rent and machines.
Activity. Write the offer card, the proof list and the terms sheet. Test them with three customers and note every point where they hesitated.
Standard to meet. Check that promise, proof and price are consistent, fit the terms on one page, and record three customer reactions.
Module 4 Run the work step by step 5 hApply
Good operations make results repeatable. For manufacturing business, write each step so a new person could follow it on their first day, and measure each step.
- In manufacturing business: Plan: materials, process steps, inspection points, packing, dispatch.
- Map the process from first contact to paid and closed. Typical stages: enquiry, quote, preparation, delivery of the batch, check, payment, follow-up.
- Name the key resource at each stage: a documented process and gauges. Note what happens if it is missing.
- Write a one-page standard procedure per stage: who, what, tool, time, record.
- Choose three measures: speed, quality (errors per 100) and customer rating. Review them every week.
- Fix the cause of a defect, not the symptom. Ask 'why' five times and record the answer.
Worked example. Stage record: 'Prepare. Owner: lead. Time: 30 min. Tool: checklist. Record: signed sheet. Defect found on 1 of 7 batches last week; cause: missing check on a documented process and gauges; fix: add check at start, review next Friday.'
Second worked scenario. Scenario: of 30 batches last month, 2 had a defect traced to a documented process and gauges. Question: what is the defect rate and what is your first action? Model answer: about 7 defects per 100; stop the cause (add a check at the start), correct affected customers, log the cause, and re-measure next week.
Activity. Draw the process map and write procedures for the two riskiest stages. Run each once and time it.
Standard to meet. Write procedures a stranger can follow, record weekly numbers for each measure, and trace one defect to a root cause.
Module 5 Safety, quality and risk 4 hEvaluate
The most serious risk in this field is defects that pass inspection. A calm, written risk routine protects people first and the business second.
- In manufacturing business: Machine guarding, lockout and noise are hazards.
- List ten things that could go wrong. Score each for how likely (1 to 5) and how serious (1 to 5). Multiply and sort.
- For the top five, choose a control: remove the hazard, replace it, guard it, train people, or use protective gear, in that order of preference.
- Write who does what in an emergency, and rehearse it once a quarter.
- Keep an incident and near-miss log. Near-misses are free lessons.
- Check that insurance and legal duties match the risk you actually carry.
Worked example. Risk row: 'Hazard: defects that pass inspection. Likelihood 3, severity 5, score 15. Control: written check before each batch, trained staff, log sheet. Owner: site lead. Review monthly.'
Second worked scenario. Scenario: a near-miss occurs: defects that pass inspection nearly happened but no one was hurt. Question: what do you do in the next 24 hours? Model answer: make safe, record the event, ask the five whys, add or tighten one control, brief the team, and set a review date; near-misses count as lessons, not blame.
Activity. Build a ten-row risk register and a one-page emergency plan. Run a ten-minute drill with a peer and note two improvements.
Standard to meet. Rank controls by preference for the top risks, run the drill, and start the log. Where a regulation applies, follow the official rule.
Module 6 People, skills and service 4 hApply
People deliver the promise. Define roles, train to a standard and give feedback in the open.
- In manufacturing business: Train operators with work instructions.
- Write a role card for each person: purpose, five tasks, the standard for each, and who to ask for help.
- Train by showing, doing with support, then doing alone with a check. Record sign-off per task.
- Set service rules for answering customers: reply times, tone, how to apologise and fix.
- Hold a ten-minute team check each day: yesterday's problem, today's plan, one risk.
- Build a growth path: what a new person can do in week 1, month 3 and month 12.
Worked example. Training record: 'Task: process a complaint. Shown 2 May; done with support 4 May; done alone 8 May, checked: apology, fix, follow-up call. Signed by lead.'
Second worked scenario. Scenario: a new hire completes training but a customer complaint shows a skipped step. Question: whose gap is it? Model answer: first the system: check the role card, the training sign-off and the checklist; then coach the person and fix the document so the step cannot be skipped.
Longer notes. Write a standard work sheet for each station with steps, times and quality points, and train each operator on it. Run a short shift briefing on the plan, safety and quality problems. Teach lockout, cleaning and machine guarding by showing each step. Rotate operators so two people can run every machine. Keep a training matrix and confirm the safety and working-hours rules for each machine station. Hold a five-minute huddle at each shift start to review yesterday's scrap and today's plan, and write numbers on a board. Operators who see results improve are more willing to follow standards and report problems early.
Extra worked example. Scrap cost 4 percent of a batch's variable cost, R$ 248. After training it fell to 2,5 percent, R$ 155, saving R$ 93 per batch. Over 30 batches that is R$ 2.790. Training 4 operators for 2 days at R$ 120 costs 4 x 2 x R$ 120 = R$ 960. The times and rates are classroom assumptions, not market data. Net gain in month one is R$ 2.790 - R$ 960 = R$ 1.830.
Activity. Write two role cards and a training plan for one new hire. Role-play a hard customer conversation twice and review.
Standard to meet. Write role cards with measurable standards, show the sign-off steps in training, and write the service rules in plain words.
Module 7 Money: cost, price and break-even 5 hAnalyse
A business lives or dies on a few numbers. Know your contribution per unit, your fixed costs and the volume you need.
- In manufacturing business: Cost per batch includes scrap; track yield.
- Contribution per batch = price minus variable cost. Fixed costs are paid whether you sell or not.
- Break-even units = fixed cost divided by contribution. Plan to pass it by a safe margin.
- Make a 12-month cash plan. Cash timing matters as much as profit: customers may pay late, suppliers may want money first.
- Keep money for business and money for the owner apart.
- Test the plan: what if sales fall by a quarter, or cost rises by a tenth?
Worked example. Worked example, all figures in reais: price R$ 9.000, variable cost R$ 6.200, contribution R$ 2.800 per batch. Fixed cost R$ 45.000 a month. Break-even = R$ 45.000 / R$ 2.800 = 16,07, so 17 batches a month. At 30 batches a month, profit = R$ 2.800 x 30 - R$ 45.000 = R$ 39.000. These are teaching figures that belong to this example only; later examples and the case study use their own figures. Use your own.
Second worked scenario. Scenario: sales fall to 22 batches a month. Question: what is the monthly result? Model answer: R$ 2.800 x 22 - R$ 45.000 = R$ 16.600; compare with break-even of 17 batches and decide whether to cut fixed cost or raise volume first. Teaching figures only.
Activity. Build your own table: price, variable cost, contribution, fixed cost, break-even and a downside case at 75% of sales. Show it to a peer or mentor.
Standard to meet. Calculate correctly, give every figure a source or mark it as an assumption, and show a downside case.
Module 8 Grow, measure and renew 4 hEvaluate
Growth should follow proof. Measure, learn, then add; and keep returning to the customer.
- In manufacturing business: Grow with lean improvement and a second shift.
- Pick one growth lever at a time: new customers, a higher repeat rate, a better price, or a new offer.
- Set one measurable target for 90 days, such as 'raise repeat customers from 20% to 30%'.
- Ask each customer how they found you, and record it. Spend more where the record shows results.
- Review monthly: numbers, defects, complaints, cash. Write three decisions each time.
- Plan the renewal of licences, equipment and skills a year ahead.
Worked example. 90-day plan: 'Lever: repeat customers. Action: follow-up call after every batch. Target: repeat rate from 20% to 30%. Check: weekly count. Review date: day 45 and day 90.'
Second worked scenario. Scenario: you can add 6 batches a month by one of two levers: a follow-up call to past customers or a price rise of R$ 900 to R$ 9.900. Question: how do you choose? Model answer: test the cheaper reversible lever first (the call), measure for 30 days, and only then try the price change, so you can tell which one worked.
Longer notes. Record every batch: date, quantity, scrap, downtime, rework and customer returns. Report weekly output and cost per batch to the team. Compare buyers by volume, price and payment time. Plan maintenance before breakdowns, and keep spares for the parts that fail often. Ask buyers for a forecast so purchases of raw materials can be planned. Review prices when material costs move. Photograph the production board each Friday and keep the weekly figures in one file. After a quarter you will see patterns in downtime and scrap that daily noise hides, and you can fix the worst cause first.
Extra worked example. You made 30 batches for three buyers: 15, 10 and 5. Revenue is 30 x R$ 9.000 = R$ 270.000 and variable cost is 30 x R$ 6.200 = R$ 186.000. After R$ 45.000 fixed cost, profit is R$ 39.000. The scenario volumes are worked-example assumptions, not market data. If the buyer of 5 batches leaves, 25 batches give 25 x R$ 2.800 - R$ 45.000 = R$ 25.000, a fall of R$ 14.000.
Activity. Write a 90-day plan with one target, three actions and a review date. Present it in five minutes and take questions.
Standard to meet. Set a measurable, dated target, break the actions down small enough to start this week, and put the review date in the calendar.