Pearl Polymer Ltd.

Objective

Pearl Polymer popularly known as Pearl Pet is in house ware brand of Pearl Polymers which has been in industry since 1984. Their Products are made of virgin plastics which are universally approved by USFDA, EU Directive 2002/72/EC, BIS IS:12252 -1987 and other regulating bodies for Food, Beverage and Water storage.

Problems they were facing are:

• Lack of planning and scheduling.
• Wrong Formulation of chemical composition causes the wrong packaging and labelling.
• While a lot of actual labelling and carton design is done in house, these are all printed externally which means subcontractor lead times need tight monitoring and accurate management.
• Not able to optimize Inventory level due to lack of real time stock visibility

Solution

• Implemented NAV 2013R2 to meticulously control its packaging lines, all of which have varied capabilities.
• Implemented a custom APS rule so that orders could be campaigned in time cycles to minimize changeover times and increase efficiencies.
• Manufacturing module was customized to address key requirements like, inventory optimization, production efficiency optimization, effective material planning and production schedule, effective forecasting, and defining plant wise manufacturing process

Results

• Real-time inventory tracking facilitated automated ordering to vendors, thereby maintaining optimum stock levels.
• ‘Order to Production’ time slashed to 1/3rd of the original.
• Ability to automatically plan packaging runs by the campaign.
• Smooth Planning of orders thus giving greater visibility of capacity issues