Plastic packaging · 2024
Stock that matches the books in three months
A packaging plant moved all receipts, issues and stock by lot into one system and tied material issues to production orders.
Sample content — replace with real figures before publishing.
Results
Stock variance at count
1.5%
Before 12% → After 1.5%
Weekly planning time
3 hours
Before 2 days → After 3 hours
Stoppages from material shortage
1 per month
Before 9 per month → After 1 per month
Context
The raw material and finished goods warehouses each ran on their own spreadsheet. Every stock count was off, and the production plan kept changing because the right resin grade had run out.
What we did
- Raw materials, work in progress and finished goods are managed by lot and location.
- Every material issue is tied to a specific production order.
- Material requirements are recalculated automatically when the plan changes.
- A stock dashboard and low-stock alerts for the purchasing team.
Results
After three months in operation, stock counts almost match the system. The planning team builds the weekly schedule in a morning instead of two days.