BS FOILS PVT LTD
BS FOILS PVT LTD
BS FOILS PVT LTD
Making daily execution predictable at BS FOILS PVT LTD

Making daily execution predictable at BS FOILS PVT LTD

Making daily execution predictable at BS FOILS PVT LTD

The team moved from ad-hoc tracking to one live view of WIP, shortages, and readiness. (case 540)

20%

Improvement in on-time dispatch

20%

Improvement in on-time dispatch

31%

Reduction in inventory mismatch cases

31%

Reduction in inventory mismatch cases

6 days

Faster internal approvals cycle

6 days

Faster internal approvals cycle

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About BS FOILS PVT LTD

About BS FOILS PVT LTD

BS FOILS PVT LTD operates from Faridabad and builds structures for OEM customers. As a micro-scale fabrication unit running extended shifts during peak weeks, they work with a make-to-order model and two warehouses. They needed a centralised workflow to reduce daily follow-ups and keep commitments predictable.

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Fabrication

Industry

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Fabrication

Industry

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Micro

Company Size

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Micro

Company Size

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Faridabad

Location

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Faridabad

Location

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Material planning for steel/consumables and outside processing control

Use Cases

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Material planning for steel/consumables and outside processing control

Use Cases

Challenges

Painting status was confirmed via Excel-based plan, so WIP clarity broke during single shift.

Pipes shortages showed up late, causing emergency buys and delays on enclosures.

Dispatch dates were scheduled before checks for surface finish, causing reshuffles (month-end GST pressure).

Workcentre progress captured at source

Workcentre progress captured at source

Workcentre progress captured at source

Earlier, BS FOILS PVT LTD relied on whiteboard planning and calls to confirm bending 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 staggered shifts.

Earlier, BS FOILS PVT LTD relied on whiteboard planning and calls to confirm bending 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 staggered shifts.

Requirement-driven buying rhythm

Requirement-driven buying rhythm

Requirement-driven buying rhythm

Earlier, buying for plates 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 enclosures, 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 two warehouses.

Earlier, buying for plates 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 enclosures, 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 two warehouses.

Paperwork + packing visibility

Paperwork + packing visibility

Paperwork + packing visibility

Earlier, dispatch dates were committed before checks on job sequencing. 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 export buyers.

Earlier, dispatch dates were committed before checks on job sequencing. 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 export buyers.

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Built by IIT & IIM founders

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AI-Run Factory

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Built by IIT & IIM founders