A prominent paper mill was grappling with significant inefficiencies in its production processes. Despite having sufficient demand and capacity, the plant faced:
The result? Sluggish cash flows, rising operational costs, and a widening gap between potential and actual performance.
We set out to address both the productivity bottlenecks and the capital inefficiencies—by building system discipline, enforcing daily routines, and creating a culture of accountability across the shop floor.
Our approach focused on:
Right-sizing inventory norms for raw materials and finished goods
The engagement kicked off with an intensive diagnostic to map existing gaps. What followed was a fast-paced 90-day execution plan, driven by floor-level coaching, data-backed reviews, and cross-functional ownership.
Enforced structured maintenance schedules and empowered operators to perform basic preventive checks, reducing surprise breakdowns.
Introduced shift-wise tracking of production vs. plan and implemented visual boards to track key metrics—bringing real-time visibility and accountability to the shop floor.
Codified shift-wise SOPs and coached supervisors to ensure strict compliance, reducing variability in performance.
Recalibrated inventory holding norms to align with actual consumption patterns, freeing up blocked capital without affecting production continuity.
Optimized scheduling across product families to reduce changeover time and balance machine workloads.
Ran focused 2-week sprints to solve specific pain points—like reel changeover times and paper break issues—through employee-led initiatives.
In just 90 days, the plant witnessed a dramatic transformation:
Higher output with the same asset base, driven by better planning and reduced downtime.
Optimized inventory levels led to significant capital release without disrupting operations.
Sustained preventive maintenance and better shift control resulted in fewer stoppages.
Performance gaps across shifts narrowed, driving better throughput and quality control.
Result: A high-performing plant with better cash flows, stronger operational discipline, and a more motivated shop floor team.
→ Delivered in just 3 months.
