Manufacturing · MFG-02
Boosting Efficiency in Plastic Moulding Operations through Lean Transformation and Data-Driven Planning
Business challenge
The manufacturer of plastic molded furniture and industrial plastic products required a structured system to address high inventory, long and variable manufacturing lead times. The objective was to improve profitability by aligning sales, production, inventory, capacity, and management planning across its furniture, crate, pail, household, and industrial moulding businesses.
What we did
Mapped the complete order-to-dispatch value chain covering sales, purchase, mixing, moulding, printing, grinding, raw material, semi-finished goods, finished goods, and receivables by applying time-based Value Stream Mapping.
Built a data template and analysed production capacity, cycle time, machine utilisation, downtime, changeovers, defects, material consumption, inventory levels, and product-machine allocation to identify operational bottlenecks and improvement opportunities.
Standardised raw material, semi-finished goods, finished goods, BOMs, capacities, and data-capture systems, and implemented ERP-ready measurement templates and KPI benchmarks.
Analysed SKU-wise sales and profitability to identify profitable, loss-making, slow-moving, and inventory-intensive products and support product-portfolio rationalisation.
Developed SOPs covering the business cycle from Annual Operating Planning to sales returns and customer complaints, and trained the management team to prepare an effective AOP and run the company through structured targets, budgets, reviews, and accountability mechanisms.
