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Overview

The client manufactures ropes, and twines made of poly-propylene and poly-ethylene. The management sits at a remote destination 80 kms away from the manufacturing facility. The product is authorized by Bureau of Indian Standards and the manufacturing facility is ISO 9001 certified. 150 Metric Tonne of ropes an twines are produced each month.

Current Situation

The client wished for systems that could monitor production performance in manufacturing facility without a visit by top management every day. Lack of mobility in the data they monitored meant that immediate reporting about performance was impossible. The management identified multiple other data points to be tapped. Depending on worker to collect the data, however, raised questions on the quality, timeliness, accuracy and consistency of data. Client focuses extensively on the quality of their products and hence wished for process quality monitoring of measures.

Solution

Process was established that enabled the data collection process, independent of the worker Staff involved in support processes were given well defined job requirements and the data gathering responsibility. Identified critical to quality parameters & included in the data gathering processes. Enabled a daily shift-wise summary of the production process which is communicated to the management on a regular basis. Developed flexible costing mechanism that incorporated real-time fluctuation in cost of raw material to decide the selling price of each of the finished goods. Instituted activity based costing report every time an equipment is run and helped in efficient tracking on production costs

Results

Costing method instituted provided real time costs and removed approximations from the process completely. Automated reports and remote tracking saved top management personnel 7-8 weekly 200 km visits. Visit is only required when a new production plan begins. High quality production environment targeting 10-15% decrease in waste instances over a six month period. The solution delivered helps management evaluate performance of man, machine and resources remotely.