KCL Mould Tech India Private Limited

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KCL Mould Tech India Private Limited improved delivery predictability with structured execution

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

25%

Reduction in daily coordination time for plastics work

25%

Reduction in daily coordination time for plastics work

34%

Reduction in excess inventory across store and production

34%

Reduction in excess inventory across store and production

6→3 days

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

6→3 days

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

About KCL Mould Tech India Private Limited

KCL Mould Tech India Private Limited is a small plastics manufacturing unit based in Tiruvannamalai. 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.

Plastics

Industry

Plastics

Industry

Small

Company Size

Small

Company Size

Tiruvannamalai, India

Location

Tiruvannamalai, India

Location

RM-to-FG traceability + mould-wise planning

Use Cases

RM-to-FG traceability + mould-wise planning

Use Cases

Challenges

Short/excess at dispatch led to urgent rework and multiple trips between store and floor.

Month-end reporting became a rework exercise because data lived in multiple files and chats.

Batch/lot traceability gaps made it hard to isolate which raw material caused a quality issue.

Dispatch readiness built into the daily routine

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 a single system of record connecting sales, purchase, production and dispatch so everyone worked off the same status. Dispatch checklists were run a day ahead so invoicing, packing and transporter booking stayed aligned. The practical outcome was smoother handovers between departments and more predictable daily execution.

Stabilising planning with live WIP and material signals

Earlier, masters and transactions were split across Excel, accounting exports and WhatsApp updates. This broke down at month-end; teams rebuilt the same report multiple times and still debated the numbers. We implemented structured stage-wise tracking and checklists so work moved forward only when prerequisites were met. Masters were cleaned once, and daily reporting pulled from the same transactions instead of manual consolidation. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

Cleaning masters to make reports match reality

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. The practical outcome was that teams stopped re-entering the same data and acted on exceptions early.

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