Cases

Defining an Operations Strategy for a Glass Bottles Manufacturer

Challenge

The client was a glass bottles manufacturer focusing on the perfumery segment with two plants in Igatpuri, Maharashtra. The lack of process clarity led to critical issues, the most severe being customer rejects due to unacceptable quality. Other issues included long lead time in new product development, planning inadequacies impacting delivery schedules, inadequate mould maintenance leading to quality issues, infrequent monitoring of fore-hearth conditions etc. The top management perceived the need to review the operations, identify improvement opportunities and document the same in the form of an operating procedure.

Our Approach

UC took the following steps for this project:

  • Reviewed all functions viz. like- planning, procurement, dispatch, marketing, new product development and plant management (covering furnace monitoring, mould and machine maintenance etc.) keeping quality as the pivotal function
  • Introduced a dynamic system of sampling (including on-line, off-line and PDI) where accepted quality level (AQL) for categories of defects (major and minor) could be alternated
  • Developed a staffing plan for supervisory staff requirements, especially for the last shift
  • Outlined a framework for vendor management, especially for packing materials as breakage of glass in transportation was a key issue
  • Reviewed mould maintenance practices conducted to remove the impact of inefficient practices on quality
  • Reviewed overall plant management including frequency of monitoring of critical parameters
  • Across six key functions, UC covered a total of 30 operations, which were benchmarked, improved upon, and documented as standard procedures
  • For each of the 30 processes, UC also defined key metrics for monitoring process health and reporting the same in the form of a management information system (MIS)
  • Drafted a detailed action plan to help drive the implementation of recommendations

Impact

A review and redesign of the operations of the organisation to address issues like- long lead time, inadequate maintenance, quality issues, delivery issues etc.