Foil Crafts
Foil Crafts
Foil Crafts
Foil Crafts tightened shop-floor control with a centralised workflow

Foil Crafts tightened shop-floor control with a centralised workflow

Foil Crafts tightened shop-floor control with a centralised workflow

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

34%

Reduction in daily coordination time for auto ancillary work

34%

Reduction in daily coordination time for auto ancillary work

22%

Reduction in excess inventory across store and production

22%

Reduction in excess inventory across store and production

8→3 days

Improvement in order-to-dispatch lead time with fewer last-minute follow-ups

8→3 days

Improvement in order-to-dispatch lead time with fewer last-minute follow-ups

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About Foil Crafts

About Foil Crafts

Foil Crafts is a small auto ancillary manufacturing unit based in Ghaziabad. 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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Auto Ancillary

Industry

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Auto Ancillary

Industry

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Small

Company Size

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Small

Company Size

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Ghaziabad, India

Location

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Ghaziabad, India

Location

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Batch-wise traceability for parts and rejections

Use Cases

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Batch-wise traceability for parts and rejections

Use Cases

Challenges

Rejections were logged on paper; rework cost showed up only after dispatch was missed.

Transporter availability was confirmed late, so finished goods piled up near the gate.

No simple view of vendor-wise delays, so the same issues repeated every month.

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. For auto ancillary operations in Ghaziabad, this reduced dependence on a single person for updates. The practical outcome was fewer escalations, faster decisions, and dates that changed less often.

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. For auto ancillary operations in Ghaziabad, this reduced dependence on a single person for updates. The practical outcome was fewer escalations, faster decisions, and dates that changed less often.

Reducing month-end surprises with traceable transactions

Reducing month-end surprises with traceable transactions

Reducing month-end surprises with traceable transactions

Earlier, dispatch readiness depended on people coordinating invoice, packing and transporter on calls. This broke down when transporter slots moved; finished goods were ready but paperwork and packing lagged behind. We implemented structured stage-wise tracking and checklists so work moved forward only when prerequisites were met. Dispatch checklists were run a day ahead so invoicing, packing and transporter booking stayed aligned. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Earlier, dispatch readiness depended on people coordinating invoice, packing and transporter on calls. This broke down when transporter slots moved; finished goods were ready but paperwork and packing lagged behind. We implemented structured stage-wise tracking and checklists so work moved forward only when prerequisites were met. Dispatch checklists were run a day ahead so invoicing, packing and transporter booking stayed aligned. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Stabilising planning with live WIP and material signals

Stabilising planning with live WIP and material signals

Stabilising planning with live WIP and material signals

Earlier, vendor follow-ups were call-driven and depended on whoever remembered to push. This broke down during peak load—approvals got delayed and committed dates slipped without a simple exception view. We implemented a centralised workflow where each order, material requirement and update had a clear owner and timestamp. The purchase team used one follow-up queue, logged committed dates, and escalated exceptions early. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Earlier, vendor follow-ups were call-driven and depended on whoever remembered to push. This broke down during peak load—approvals got delayed and committed dates slipped without a simple exception view. We implemented a centralised workflow where each order, material requirement and update had a clear owner and timestamp. The purchase team used one follow-up queue, logged committed dates, and escalated exceptions early. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

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