Every month-end at Mehta Corrugation in Bhiwandi was the same: the numbers didn't add up. Raw material going in, finished goods going out — but the difference was always higher than expected. The owner knew they were losing material somewhere, but couldn't say where.
What actually causes this — and what fixes it
"Material loss — this is the answer that stops being acceptable once you can see what it actually means."
The operators weren't stealing. The machines weren't broken. The problem was simpler: nobody was logging quantity in and quantity out at each stage. Wastage at lamination looked the same as wastage at die cutting. Everything was 'thoda wastage hua' — some wastage happened.
Clicarity made quantity logging part of every stage update. Within a month, Mehta Corrugation could see exactly where the losses were occurring — and how much. The lamination stage was responsible for 60% of their wastage. One process change, and monthly material costs dropped by 12%.