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Customer
Title
Muscat Leading Plastic LLC
Industry
Plastic Manufacturing
Project Duration
One year
Achievement
15% Increase in Sales
Sales
Challenges
Customer Relation not Managed
Poor Collection
Poor Sales
Bulk of Overdue Receivables
Solutions
Introduced Customer Relationship Management System
Developed Sales Incentive Schemes
Regular Sales Reviews
Commenced Lead Appreciation Scheme
Improved Visibility Between Finance & Sales Teams
Manufacturing
Challenges
Overproduction
Delayed Production
Lack of Monitoring
Frequent Equipment Breakdown
Solutions
Created Master Order Register
Started Daily Production Tracking
Started Individual Order Progress Tracking
Improved Order Processing Transparency (between Sales & Production teams)
Starting Production Planning & Prioritisation Reviews (between Sales & Production teams)
Starting Reporting System (to collect data of machine breakdowns)
Starting Preventive Maintenance System
Starting Machinery Efficiency Charts
Introduced Machinery Non-Productive Time Categorisation
Supply Chain
Challenges
Uncontrolled Expenditures
Uncontrolled Procurement (by any team member)
Lack of Inventory Management
Critical Inventory Items Not Identified
Regular Zero Stock Situations
Critical Inventory Items Not Identified
Solutions
Built Clear Procurement Prioritisation and Approval Process
Identified Responsible Person
Revised Inventory Management System
Identified Min-Max for all stock items (including Raw Materials, Consumables & Spares)
Started Computer Based Inventory Management System
Converted Procurement Process to Kanban Flow (with clear Roles & responsibilities)
Commenced Regular Procurement review (by Procurement, Materials & Finance teams)
Human Resources
Challenges
Mistrust, Multi & Micro management
Lack of Competencies
Lack of Communication
Poor Work Attendance Monitoring
Poor Morale
Poor Employee Involvement
Lack of Accountability
Lack of Competition Spirit
Solutions
Mapped Roles & Responsibilities
Mapped Required Skills & Competencies
Developed Training Matrix
Developed Training Materials for In-house training
Started Performance Appraisals
Developed Fair Consequence Management
Developed Performance Incentification