Flexible Intermediate Bulk Container is a growing industry in the country and the demands for jumbo bags are on the rise lately. The FIBC market is growing at a rate of 7.3% and will soon become an indigenous contributor to the GDP of the country.
Faber Infinite has been associated with several clients dealing in FIBC and woven sacks industry, assisting in building competitiveness and productivity.
About the Client
Client is one of the leading manufacturers of a number of packaging solutions including PP Woven Fabrics, PP woven sacks, FIBC Bags, BOPP Bags, Block Bottom Bags, Bale Wrap Fabrics, Woven GeoTextiles, Woven GroundCovers, Slit Fence and many more. Besides these, the client also deals and manufacture PP Wrapping Fabric, Low GSM PP Baling Fabric, PP Clear Sheets and Polylined Woven Sacks.
Packaging Solution is a need of the modern and constantly evolving industry and is being currently used in various industries including fertilizer, cement, sand, food grains, sugar, cattle feed, fish meal, pulses, spices, dates, agro products, minerals, resin, polymers, rubber, etc.
Challenges faced
To increase productivity, manpower efficiency and retention are one of the major factors that drive this entire substratum. Also, training plays a vital role in improving the productivity numbers. Besides this, the company also faced problems in reducing the time span for implementing the changes. Furthermore, the processes also needed to be quick and nimble to increase the manpower productivity.
How Team Faber approached the problems?
Team Faber has been an active participant and has been known to solve problems like these with its uniqueness and specially designed framework of Operational Excellence.
One of the challenges in the value stream was the inability to cater to the downstream requirements. There were inefficiencies at a bottleneck department feeding to one of most labor-intensive finishing function. When the bottleneck section was itself was facing a lot of complications, the manpower was not able to deliver in two shifts.
Team Faber identified all the wastes/ inefficiencies that had crept in and actually affecting its efficiency. Moreover, the focus was shifted to upstream input materials and its regular inflow in the manufacturing units. Also, the waste of waiting was eliminated with the help of Faber Infinite solutions. Besides this, Team Faber also worked in the assembly section (stitching section) where layout change and implementation of time and motion study led to phenomenal manpower productivity improvement.
Results delivered
Team Faber helped the client to bring whopping 40% improvement in bottleneck section production per day. Also, the number of shifts were reduced by 50% and hence the organization was able to save around 30% on manpower costs per kilogram of production. Moreover, the wastages were reduced by more than 30% in the production plant. The company was benefitted with the implementation of designs and plans arranged by Team Faber and also gained financial benefits.
Overall, Team Faber delivered a massive 50% improvement in the entire throughput.
At Faber Infinite, we believe in ‘Make in India’ and have always supported the dream of making India more productive. This National Productivity Week, let us take a pledge to make India more productive and support make in India. We believe in the concept of ‘Make in India’ and support the sole motive of making India a better place to operate and making India a first world country.
