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ELCIA Cluster

From scattered sheets to one workflow: ELCIA Cluster's ops reset

A practical shift from WhatsApp/Excel coordination to trackable daily execution.

14%

Reduction in excess inventory for packaging work

14%

Reduction in excess inventory for packaging work

31 mins→16 mins

Faster daily MIS and stock reporting across store and production

31 mins→16 mins

Faster daily MIS and stock reporting across store and production

₹12L/yr

Avoided expedite, rework and unplanned purchase costs with fewer last-minute follow-ups

₹12L/yr

Avoided expedite, rework and unplanned purchase costs with fewer last-minute follow-ups

ELCIA Cluster at a glance

ELCIA Cluster is a micro packaging 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.

Packaging

Industry

Packaging

Industry

Micro

Company Size

Micro

Company Size

Bangalore, India

Location

Bangalore, India

Location

WIP tracking across printing–lamination–slitting–dispatch

Use Cases

WIP tracking across printing–lamination–slitting–dispatch

Use Cases

Challenges

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

Payment follow-ups depended on WhatsApp threads; disputes re-opened invoices at month-end.

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

Vendor coordination with structured PO follow-ups

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 centralised workflow where each order, material requirement and update had a clear owner and timestamp. 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.

Implementation: Centralised workflow with clear owners

Earlier, collections follow-ups were scattered and disputes reopened older invoices. This broke down on part-payments; the receivable view changed daily and escalations increased. We implemented structured stage-wise tracking and checklists so work moved forward only when prerequisites were met. Collections follow-ups moved to a single list with dispute tagging so teams stopped chasing the wrong invoices. Over time, the team built confidence because the numbers matched what they saw on the floor. The practical outcome was smoother handovers between departments and more predictable daily execution.

Before: Too many moving parts, no single view

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 a single system of record connecting sales, purchase, production and dispatch so everyone worked off the same status. QC marked holds against lots, and planners saw only cleared stock as available for production. The practical outcome was fewer escalations, faster decisions, and dates that changed less often.

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