Introduction and Industry Context
Modern packaging serves diverse sectors—including food, pharmaceuticals, consumer goods, and electronics—demanding robust traceability, fast change management, and consistently high quality. Increasing complexity in materials (films, foils, laminates), design revisions, and regulatory requirements (FDA, FSSAI, ISO) create operational challenges for packaging manufacturers relying on manual systems.
Common pain points include fragmented bill of materials (BoM) control, lack of real-time shop-floor visibility, scattered compliance documentation, and unpredictable costing—leading to production delays, compliance risks, and unexpected margin variances.
Key Challenges
- Complex Multi-Material BoMs
- Manual & Delayed Production Tracking
- Disparate Quality & Certification Records
- Costing Inaccuracy & Inventory Risks
Our Solutions
- Smart BoM Control & ECR Integration
- Real-Time Shop-Floor Data Capture
- Centralized Quality & Compliance Management
- Live Costing, Inventory Visibility & Predictive Planning
Implementation Approach
- Discovery & Blueprinting: Workshops with engineering, production, quality, procurement, and finance teams to map pain points and define roles.
- System Configuration: Deploying SAP Business One core modules and custom enhancements for packaging-specific needs.
- Integration & Testing: Connecting to shop-floor systems (PLCs, barcode scanners), migrating legacy data, and thorough UAT.
- User Training & Go-Live Support: Role-based training with a helpdesk and pilot rollout, followed by full facility coverage.
Results & Business Impact (90 days)
| Metric | Improvement | Baseline | Post-Implementation |
|---|---|---|---|
| Rework Ratey | Significant Drop | 8% | 4.7% |
| Audit Preparation Time | Drastically Lowered | 40 hours | 6 hours |
| Month-End Cost Variance | Eliminated | ₹2.5 million | ₹0 |
| Lead Time (Design-to-Launch)e | Reduced | 20 days | 15 days |
Why Clockwork Business Solutions?
- Domain Customizations: Extensions for material traceability, BoM version control, and packaging compliance workflows.
- Seamless MES Integration: Real-time production monitoring from print line to lamination and packing.
- End-to-End Traceability: Serial and lot tracking, automating quality gate enforcement.
- Scalability: Supports rapid prototyping and mass production for various packaging formats.
Conclusion
- Expansion to global facilities for standardized processes and reporting.
- Exploring IoT-based predictive maintenance for converting and packing lines, and enhanced analytics integration with SAP Analytics Cloud.
This case study illustrates how a focused ERP implementation can revolutionize packaging manufacturing, delivering measurable ROI and positioning the company for sustainable growth in a competitive market.