Sookshm Case Study - Plastic Rope Manufacturing Facility

1. Implementation of performance measurement system at a
Ropes Manufacturing facility
Kala Amb, Himachal Pradesh
The client is a subsidiary of a major tile manufacturing conglomerate in India. The
client manufactures ropes made of poly-propylene and poly-ethylene with a monthly
capacity of 150 Metric Tonne/month. The management sits at a remote destination
than the manufacturing facility. The company is an ISO 9001 certified
“Great people to work with, get to learn a lot
from senior leadership. Their implementation
created a better work
environment and provided opportunities for my
internal team to grow.”
Regd. Office :- 31 & 42 , Community Centre, Mezzanine Floor, Basant Lok, Vasant Vihar- 110057. (India)
Ph : +91 11 26144448- 49, Fax :- +91 11 26142642 @ E Mail: mayank@sookshm.co.in
Website: www.sookshm.co.in

2. Situation
• The client wished for systems that could monitor production performance
in manufacturing facility without a visit by top management every day.
• Lack of mobility in the data they monitored meant that immediate reporting
about performance was impossible.
• The management identified multiple other data points to be tapped. Depending on
worker to collect the data, however, raised questions on the quality, timeliness,
accuracy and consistency of data
• Client focuses extensively on the quality of their products and hence wished for
process quality monitoring of measures.
Sookshm Action
• Process was established that enabled the data collection process, independent of
the worker
• Staff involved in support processes were given well defined job requirements and
the data gathering responsibility
• Identified critical to quality parameters & included in the data gathering processes
• Enabled a daily shift-wise summary of the production process which
is communicated to the management on a regular basis.
• Developed flexible costing mechanism that incorporated real-time fluctuation in
cost of raw material to decide the selling price of each of the finished good
• Instituted activity based costing report every time an equipment is run and helped
in efficient tracking on production costs
RESULT
• Costing method instituted provided real time costs and removed
approximations from the process completely
• Automated reports and remote tracking saved top management personnel 7-8
weekly 200 km visits. Visit is only required when a new production plan begins.
• High quality production environment targeting 10-15% decrease in waste
instances over a six month period
• The solution delivered helps management evaluate performance of man,
machine and resources remotely
Regd. Office :- 31 & 42 , Community Centre, Mezzanine Floor, Basant Lok, Vasant Vihar- 110057. (India)
Ph : +91 11 26144448- 49, Fax :- +91 11 26142642 @ E Mail: maynk@sookshm.co.in
Website: www.sookshm.co.in