CSR FORGING PVT. LTD.
CSR FORGING PVT. LTD.
CSR FORGING PVT. LTD.
Reducing coordination overhead at CSR FORGING PVT. LTD.

Reducing coordination overhead at CSR FORGING PVT. LTD.

Reducing coordination overhead at CSR FORGING PVT. LTD.

Exceptions started surfacing early, reducing daily firefighting and urgent purchases. (case 874)

₹14 L/yr

Working capital freed from slow-movers

₹14 L/yr

Working capital freed from slow-movers

7 days

Faster internal approvals cycle

7 days

Faster internal approvals cycle

12 days

Order lead time improvement

12 days

Order lead time improvement

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About CSR FORGING PVT. LTD.

About CSR FORGING PVT. LTD.

CSR FORGING PVT. LTD. operates from Patiala and builds plastic housings for distributors. As a micro-scale plastics unit running staggered shifts, they work with a make-to-stock model and two warehouses. They needed a centralised workflow to reduce daily follow-ups and keep commitments predictable.

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Plastics

Industry

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Plastics

Industry

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Plastics

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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Patiala

Location

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Patiala

Location

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Patiala

Location

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Batch/lot control and RM consumption visibility for moulded parts

Use Cases

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Batch/lot control and RM consumption visibility for moulded parts

Use Cases

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Batch/lot control and RM consumption visibility for moulded parts

Use Cases

Challenges

Packing status was reconciled via planner’s notebook, so WIP clarity broke during two shifts.

Packing status was reconciled via planner’s notebook, so WIP clarity broke during two shifts.

Packing status was reconciled via planner’s notebook, so WIP clarity broke during two shifts.

Cartons shortages showed up late, causing emergency buys and delays on moulded inserts.

Cartons shortages showed up late, causing emergency buys and delays on moulded inserts.

Cartons shortages showed up late, causing emergency buys and delays on moulded inserts.

Dispatch dates were promised before checks for colour consistency, causing reshuffles (bulk dispatch at month-end).

Dispatch dates were promised before checks for colour consistency, causing reshuffles (bulk dispatch at month-end).

Dispatch dates were promised before checks for colour consistency, causing reshuffles (bulk dispatch at month-end).

WIP visibility without chasing

WIP visibility without chasing

WIP visibility without chasing

Earlier, CSR FORGING PVT. LTD. relied on whiteboard planning and calls to confirm packing 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, CSR FORGING PVT. LTD. relied on whiteboard planning and calls to confirm packing 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, CSR FORGING PVT. LTD. relied on whiteboard planning and calls to confirm packing 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 granules 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 injection-moulded parts, 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 granules 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 injection-moulded parts, 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 granules 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 injection-moulded parts, 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.

Promise dates with readiness gates

Promise dates with readiness gates

Promise dates with readiness gates

Earlier, dispatch dates were committed before checks on colour consistency. 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 project-based customers.

Earlier, dispatch dates were committed before checks on colour consistency. 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 project-based customers.

Earlier, dispatch dates were committed before checks on colour consistency. 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 project-based customers.

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