Process Automation for Packaging Industry
For a packaging company, we built a system to automate project costing, production workflows, and inventory management. The client portal streamlined design approvals, and automation reduced bottlenecks across cutting, assembly, and finishing, leading to faster order fulfillment and lower wastage.
Client Overview
A leading packaging company specializing in custom solutions for industries such as FMCG, pharmaceuticals, and e-commerce sought to automate its operations and streamline workflows. The company faced challenges in production tracking, cost estimation, inventory management, and client coordination, which hindered scalability and efficiency.
Challenges
The client faced significant issues, including:
- Estimate Preparation: Preparing cost estimates for custom packaging projects was manual, time-consuming, and prone to inaccuracies, affecting pricing transparency.
- Complex Production Tracking: Tracking the production process manually across multiple stages, such as cutting, printing, and assembly, led to delays and inefficiencies.
- Inventory and Material Wastage: Inaccurate tracking of raw materials like paperboard, adhesives, and inks resulted in shortages and excessive wastage.
- Post-Production Coordination: Managing finishing processes such as lamination, die-cutting, and assembly caused bottlenecks in order fulfillment.
- Client Communication and Approvals: The lack of a centralized system for managing client approvals and project updates delayed production timelines.
Solution
We developed a comprehensive business process automation system tailored to the packaging industry, featuring:
- Automated Estimate Preparation: A dynamic pricing module that calculated accurate project costs based on material type, dimensions, and production complexity, significantly reducing errors.
- Real-Time Production Tracking: A centralized dashboard to monitor every stage of production, from raw material input to finished goods, ensuring timely task completion and bottleneck identification.
- Inventory Management System: Automated tracking and alerts for raw materials, reducing wastage and ensuring seamless production schedules.
- Post-Production Automation: Integrated tools to manage finishing tasks such as lamination, die-cutting, and packaging assembly, improving workflow efficiency.
- Client Portal for Design Approval and Progress Updates: A user-friendly platform where clients could upload designs, approve proofs, track order progress, and communicate with the team in real time.
Results
- 40% Faster Estimate Turnaround: Automated cost estimation improved response times and customer satisfaction.
- 35% Improvement in Production Efficiency: Real-time tracking ensured smoother workflows and on-time delivery.
- 25% Reduction in Material Wastage: Optimized inventory management minimized overstocking and understocking issues.
- 30% Faster Post-Production Processes: Automation of finishing tasks accelerated order fulfillment.
Conclusion
The end-to-end business process automation solution transformed the packaging company’s operations, enabling them to streamline production, minimize material wastage, and enhance client interactions. By addressing challenges across the production lifecycle, the company achieved greater efficiency, reduced costs, and improved scalability, cementing its position as a leader in the competitive packaging industry.
