BALAJI PROPACK
BALAJI PROPACK
BALAJI PROPACK
Creating a single source of truth for BALAJI PROPACK

Creating a single source of truth for BALAJI PROPACK

Creating a single source of truth for BALAJI PROPACK

The team moved from ad-hoc tracking to one live view of WIP, shortages, and readiness. (case 475)

₹9 L/yr

Annual savings from avoided expediting

₹9 L/yr

Annual savings from avoided expediting

21%

Improvement in on-time dispatch

21%

Improvement in on-time dispatch

22%

Reduction in inventory mismatch cases

22%

Reduction in inventory mismatch cases

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About BALAJI PROPACK

About BALAJI PROPACK

BALAJI PROPACK operates from Kachchh and builds shrink sleeves for OEM customers. As a small-scale packaging unit running single shift, 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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Small

Company Size

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Small

Company Size

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Small

Company Size

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Kachchh

Location

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Kachchh

Location

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Kachchh

Location

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Order-to-dispatch visibility for repeat SKUs and artwork approvals

Use Cases

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Order-to-dispatch visibility for repeat SKUs and artwork approvals

Use Cases

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Order-to-dispatch visibility for repeat SKUs and artwork approvals

Use Cases

Challenges

Slitting status was reconciled via whiteboard planning, so WIP clarity broke during two shifts.

Slitting status was reconciled via whiteboard planning, so WIP clarity broke during two shifts.

Slitting status was reconciled via whiteboard planning, so WIP clarity broke during two shifts.

Cartons shortages showed up late, causing emergency buys and delays on shrink sleeves.

Cartons shortages showed up late, causing emergency buys and delays on shrink sleeves.

Cartons shortages showed up late, causing emergency buys and delays on shrink sleeves.

Dispatch dates were released before checks for artwork approvals, causing reshuffles (bulk dispatch at month-end).

Dispatch dates were released before checks for artwork approvals, causing reshuffles (bulk dispatch at month-end).

Dispatch dates were released before checks for artwork approvals, causing reshuffles (bulk dispatch at month-end).

Workcentre progress captured at source

Workcentre progress captured at source

Workcentre progress captured at source

Earlier, BALAJI PROPACK relied on planner’s notebook and calls to confirm slitting 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 single shift.

Earlier, BALAJI PROPACK relied on planner’s notebook and calls to confirm slitting 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 single shift.

Earlier, BALAJI PROPACK relied on planner’s notebook and calls to confirm slitting 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 single shift.

Materials linked to live orders

Materials linked to live orders

Materials linked to live orders

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 separate RM and FG stores.

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 separate RM and FG stores.

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 separate RM and FG stores.

Fewer last-minute dispatch changes

Fewer last-minute dispatch changes

Fewer last-minute dispatch changes

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-stock 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-stock 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-stock model and distributors.

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