Balaji Print Media
Balaji Print Media
Balaji Print Media
Improving planning discipline at Balaji Print Media

Improving planning discipline at Balaji Print Media

Improving planning discipline at Balaji Print Media

The team moved from ad-hoc tracking to one live view of WIP, shortages, and readiness. (case 568)

2 days

Faster internal approvals cycle

2 days

Faster internal approvals cycle

30%

Faster month-end reconciliation

30%

Faster month-end reconciliation

₹15 L/yr

Working capital freed from slow-movers

₹15 L/yr

Working capital freed from slow-movers

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About Balaji Print Media

About Balaji Print Media

Balaji Print Media operates from Chandigarh and builds corrugated boxes for export buyers. As a micro-scale packaging unit running two shifts, they work with a make-to-order model and separate RM and FG stores. They needed a centralised workflow to reduce daily follow-ups and keep commitments predictable.

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Packaging

Industry

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Packaging

Industry

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Packaging

Industry

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Micro

Company Size

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Micro

Company Size

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Micro

Company Size

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Chandigarh

Location

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Chandigarh

Location

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Chandigarh

Location

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Job-wise WIP + wastage control for film-based packaging

Use Cases

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Job-wise WIP + wastage control for film-based packaging

Use Cases

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Job-wise WIP + wastage control for film-based packaging

Use Cases

Challenges

Inspection status was confirmed via whiteboard planning, so WIP clarity broke during two shifts. when multiple orders overlapped.

Inspection status was confirmed via whiteboard planning, so WIP clarity broke during two shifts. when multiple orders overlapped.

Inspection status was confirmed via whiteboard planning, so WIP clarity broke during two shifts. when multiple orders overlapped.

Inks shortages showed up late, causing emergency buys and delays on paper bags.

Inks shortages showed up late, causing emergency buys and delays on paper bags.

Inks shortages showed up late, causing emergency buys and delays on paper bags.

Dispatch dates were cleared before checks for roll changeovers, causing reshuffles (bulk dispatch at month-end).

Dispatch dates were cleared before checks for roll changeovers, causing reshuffles (bulk dispatch at month-end).

Dispatch dates were cleared before checks for roll changeovers, causing reshuffles (bulk dispatch at month-end).

Workcentre progress captured at source

Workcentre progress captured at source

Workcentre progress captured at source

Earlier, Balaji Print Media relied on whiteboard planning and calls to confirm inspection progress. When priorities changed, different teams carried different versions of the plan. A centralised workflow captured stage updates at source, so WIP moved with clear ownership. The daily review shifted from collecting updates to resolving exceptions. Supervisors started closing handovers on time, improving predictability during two shifts.

Earlier, Balaji Print Media relied on whiteboard planning and calls to confirm inspection progress. When priorities changed, different teams carried different versions of the plan. A centralised workflow captured stage updates at source, so WIP moved with clear ownership. The daily review shifted from collecting updates to resolving exceptions. Supervisors started closing handovers on time, improving predictability during two shifts.

Earlier, Balaji Print Media relied on whiteboard planning and calls to confirm inspection progress. When priorities changed, different teams carried different versions of the plan. A centralised workflow captured stage updates at source, so WIP moved with clear ownership. The daily review shifted from collecting updates to resolving exceptions. Supervisors started closing handovers on time, improving predictability during two shifts.

Requirement-driven buying rhythm

Requirement-driven buying rhythm

Requirement-driven buying rhythm

Earlier, buying for films was triggered after shortages hit the shopfloor. Follow-ups lived in personal reminders, so receipts slipped during busy days. Requirements were linked to live orders and corrugated boxes, creating a daily shortage list. Vendors were followed up against dates, not memory, and approvals became faster. The team reduced emergency purchases and avoided excess on slow movers across job-site plus main warehouse.

Earlier, buying for films was triggered after shortages hit the shopfloor. Follow-ups lived in personal reminders, so receipts slipped during busy days. Requirements were linked to live orders and corrugated boxes, creating a daily shortage list. Vendors were followed up against dates, not memory, and approvals became faster. The team reduced emergency purchases and avoided excess on slow movers across job-site plus main warehouse.

Earlier, buying for films was triggered after shortages hit the shopfloor. Follow-ups lived in personal reminders, so receipts slipped during busy days. Requirements were linked to live orders and corrugated boxes, creating a daily shortage list. Vendors were followed up against dates, not memory, and approvals became faster. The team reduced emergency purchases and avoided excess on slow movers across job-site plus main warehouse.

Paperwork + packing visibility

Paperwork + packing visibility

Paperwork + packing visibility

Earlier, dispatch dates were committed before checks on roll changeovers. Packing, QA clearance, and paperwork were tracked in different places. Readiness gates were added so jobs were released only when documents were complete. Customers got clearer dates, and escalations reduced because holds had visible reasons. Dispatch planning became steadier even with a make-to-order model and distributors.

Earlier, dispatch dates were committed before checks on roll changeovers. Packing, QA clearance, and paperwork were tracked in different places. Readiness gates were added so jobs were released only when documents were complete. Customers got clearer dates, and escalations reduced because holds had visible reasons. Dispatch planning became steadier even with a make-to-order model and distributors.

Earlier, dispatch dates were committed before checks on roll changeovers. Packing, QA clearance, and paperwork were tracked in different places. Readiness gates were added so jobs were released only when documents were complete. Customers got clearer dates, and escalations reduced because holds had visible reasons. Dispatch planning became steadier even with a make-to-order model and distributors.

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