Business Transformation in Plastic products manufacturing company

Company Overview:

1) Industry: Plastic Products Manufacturing
2) Location: Three Manufacturing plants with Marketing & Sales office in India
3) Markets: Domestic and Exports

Challenges:

1) Struggled with delivery issues and a significant backlog of orders.
2) High inventory.
3) Cash flow problems.
4) Reducing Profit.

Strategic Implementations:

Financial: Established KPIs, monitoring, review & control methodology
Operational Excellence: Improved overall manufacturing and supply chain flow.
Productivity Improvement: Bottleneck identification and Optimization and improving flow.
Employee Alignment: Rolled out an employee performance system aligned to company goals.
Business Review Process: Established a weekly business review mechanism involving all stakeholders.

Impactful Outcomes:

Delivery Performance: Improved from 60% to 98% in six months.
Manufacturing Lead Time: Reduced by 40% in a year.
Inventory Reduction: Achieved a 35% reduction.
Capacity Utilization: Revealed hidden capacity of 35% within one year.
Sales Growth: Increased by 40% in a year.
Profitability: Doubled in 15 months.
Cash Flow Improvement: Cash velocity increased by 25%.