How a Packaging Manufacturer
Streamlined Operations and Boosted Efficiency
Client Background
A Gujarat-based company specializing in manufacturing durable plastic drums, buckets, and pails for storage containers and packaging solutions. Serving diverse industrial sectors, they provide reliable products for storing and transporting liquids, chemicals, and oils, with a focus on durability and industrial-grade quality.
Challenge
1
Operations managed manually using paper records
2
Difficulties in production planning and tracking
3
Lack of real-time visibility into manufacturing and quality control
4
Errors, delays, and inconsistent quality due to manual processes
Solution & Implementation
Implemented a digital system for manufacturing and quality control
Manufacturing Management
Configured shift-based production management
Set up master production planning and scheduling
Created custom workflows tailored to actual manufacturing processes
Enabled daily production planning based on shift timings
Supported multiple units of measure (UoM) for flexible reporting
Defined user roles with access control (Planner, Operator, Worker)
Automated creation of manufacturing orders based on planning
Enabled tracking of total weight, average weight, and quantity produced
Implemented rejection and scrap tracking for detailed analysis
Quality Control
Designed quality control flows based on min/max tolerance levels
Integrated quality checks directly into the production process
Enabled real-time monitoring of product quality during production
Facilitated rejection logging and tracking for root cause identification
Improved overall consistency and compliance with product standards
Results
Real-time visibility into production and quality metrics
Reduced manual errors and paperwork
Improved accuracy and efficiency in production planning
Enhanced quality control and reduced scrap/waste
Clear user roles leading to better operational discipline
Conclusion
By digitizing their manufacturing and quality control processes, the client transitioned from a cumbersome manual system to a streamlined, efficient operation. This transformation has empowered them to meet growing industrial demands with confidence and improved productivity.
