The situation
The plant was always busy, yet profit kept shrinking. Wastage was "around 6–7%" according to the supervisor, but nobody could say on which machine, which shift or which orders. Reel stock in the register did not match the godown, and wrong GSM reels were sometimes used to keep the corrugator running.
What we put in place
- Reel-wise stock by GSM, BF, deckle and supplier, with a barcode on every reel
- Deckle and trim planning on each job card
- Wastage entered shift-wise and machine-wise, on the floor, on mobile
- Daily wastage report on the owner's WhatsApp
What changes
- Wastage became a daily number with a machine and shift against it
- Wrong-reel usage became visible and stopped
- Reel stock matched the system within weeks
- Typical target in such plants: 1–2 percentage points less wastage in the first 6 months
This is a representative case based on situations we commonly see in Indian factories. Company details are withheld and figures are typical ranges. Your results depend on your factory, and we will estimate them with your real numbers.