SYS Electromac Private Limited

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How SYS Electromac Private Limited reduced firefighting using a single system of record

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

52%

Reduction in daily coordination time for packaging work

52%

Reduction in daily coordination time for packaging work

33%

Reduction in excess inventory across store and production

33%

Reduction in excess inventory across store and production

3→1 days

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

3→1 days

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

About SYS Electromac Private Limited

SYS Electromac Private Limited is a medium packaging manufacturing unit based in Hyderabad. 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

Medium

Company Size

Medium

Company Size

Hyderabad, India

Location

Hyderabad, India

Location

WIP tracking across printing–lamination–slitting–dispatch

Use Cases

WIP tracking across printing–lamination–slitting–dispatch

Use Cases

Challenges

Teams worked off screenshots and old sheets; daily numbers drifted from what the shop floor saw.

Vendor committed dates were verbal; delays were discovered only after repeated calls.

WIP quantity was unknown across stages, so dispatch dates moved every evening.

Dispatch readiness built into the daily routine

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. It also made owner reviews easier because key exceptions were visible without chasing the team. The practical outcome was smoother handovers between departments and more predictable daily execution.

After: Predictable execution, fewer escalations

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 single system of record connecting sales, purchase, production and dispatch so everyone worked off the same status. The purchase team used one follow-up queue, logged committed dates, and escalated exceptions early. For packaging operations in Hyderabad, this reduced dependence on a single person for updates. 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

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 structured stage-wise tracking and checklists so work moved forward only when prerequisites were met. Supervisors started reviewing shortages at shift start and raised purchase/transfer requests before the line was blocked. Over time, the team built confidence because the numbers matched what they saw on the floor. The practical outcome was fewer escalations, faster decisions, and dates that changed less often.

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