Cuzor Labs LLP
Cuzor Labs LLP
Cuzor Labs LLP
From scattered sheets to one workflow: Cuzor Labs LLP's ops reset

From scattered sheets to one workflow: Cuzor Labs LLP's ops reset

From scattered sheets to one workflow: Cuzor Labs LLP's ops reset

Standardising approvals and handovers so teams work off the same numbers.

6 hrs→53 mins

Faster PO approval to release cycle for plastics work

6 hrs→53 mins

Faster PO approval to release cycle for plastics work

+27 pts

Increase in on-time dispatch performance across store and production

+27 pts

Increase in on-time dispatch performance across store and production

17%

Reduction in scrap/rework with fewer last-minute follow-ups

17%

Reduction in scrap/rework with fewer last-minute follow-ups

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Cuzor Labs LLP at a glance

Cuzor Labs LLP at a glance

Cuzor Labs LLP is a small plastics manufacturing unit based in Bangalore. Their day-to-day work involves coordinating orders, material availability, production execution and dispatch commitments. Earlier, updates were shared through a mix of Excel sheets, calls and WhatsApp, which made it hard to keep everyone aligned. By moving to a centralised workflow, the team standardised handovers, reduced rework in reporting, and improved execution predictability.

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Plastics

Industry

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Plastics

Industry

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Small

Company Size

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Small

Company Size

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Bangalore, India

Location

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Bangalore, India

Location

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Stock accuracy across stores and production bins

Use Cases

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Stock accuracy across stores and production bins

Use Cases

Challenges

Store stock looked fine on paper but production bins were empty when job cards started.

QC holds were not reflected in available stock, leading to accidental usage.

Production plan changed multiple times a day due to capacity conflicts and material gaps.

Before: Too many moving parts, no single view

Before: Too many moving parts, no single view

Before: Too many moving parts, no single view

Earlier, store stock, WIP and finished goods were tracked in separate sheets and message threads. This broke down whenever priorities changed—material looked available, but the line stalled due to bin-level shortages. We implemented a single system of record connecting sales, purchase, production and dispatch so everyone worked off the same status. Supervisors started reviewing shortages at shift start and raised purchase/transfer requests before the line was blocked. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Earlier, store stock, WIP and finished goods were tracked in separate sheets and message threads. This broke down whenever priorities changed—material looked available, but the line stalled due to bin-level shortages. We implemented a single system of record connecting sales, purchase, production and dispatch so everyone worked off the same status. Supervisors started reviewing shortages at shift start and raised purchase/transfer requests before the line was blocked. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Controlling rework through traceability and holds

Controlling rework through traceability and holds

Controlling rework through traceability and holds

Earlier, QC holds and rework notes were kept on paper and were not visible to planning. This broke down during rejections; without traceability, isolating root cause took days and blocked dispatch. We implemented structured stage-wise tracking and checklists so work moved forward only when prerequisites were met. QC marked holds against lots, and planners saw only cleared stock as available for production. Over time, the team built confidence because the numbers matched what they saw on the floor. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Earlier, QC holds and rework notes were kept on paper and were not visible to planning. This broke down during rejections; without traceability, isolating root cause took days and blocked dispatch. We implemented structured stage-wise tracking and checklists so work moved forward only when prerequisites were met. QC marked holds against lots, and planners saw only cleared stock as available for production. Over time, the team built confidence because the numbers matched what they saw on the floor. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Implementation: Centralised workflow with clear owners

Implementation: Centralised workflow with clear owners

Implementation: Centralised workflow with clear owners

Earlier, the daily plan was decided in fragments—by urgency, not by capacity and material signals. This broke down as soon as urgent orders came in; jobs were half-started and WIP piled up across stages. We implemented a centralised workflow where each order, material requirement and update had a clear owner and timestamp. Planning moved to a simple daily schedule linked to orders, capacity and material, reducing last-minute reshuffles. For plastics operations in Bangalore, this reduced dependence on a single person for updates. The practical outcome was smoother handovers between departments and more predictable daily execution.

Earlier, the daily plan was decided in fragments—by urgency, not by capacity and material signals. This broke down as soon as urgent orders came in; jobs were half-started and WIP piled up across stages. We implemented a centralised workflow where each order, material requirement and update had a clear owner and timestamp. Planning moved to a simple daily schedule linked to orders, capacity and material, reducing last-minute reshuffles. For plastics operations in Bangalore, this reduced dependence on a single person for updates. The practical outcome was smoother handovers between departments and more predictable daily execution.

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