How HC Boxes solved the multi-component wastage puzzle.
A single rigid box has five to six components — each travelling through its own production path. The wastage was there. But which stage? Which component? Nobody could tell — until the job was already over.
The challenge
In rigid box manufacturing, a single finished product is actually a puzzle of five to six different components — top and bottom labels, boards, trays, and accessories. Each one travels through its own production path before being assembled into the final box.
For Uday Vora, Owner of Hrimkar Creations (HC Boxes), this complexity created a problem that was impossible to solve without the right system. Sheets were entering the production line. Material was being lost somewhere. But where? At which stage? On which component?
Without granular, component-level visibility, it was impossible to pinpoint which stage — printing, lamination, or embossing — was responsible for the material loss until the job was already over. By then it was too late. The loss was written off. The same thing happened next month.
"Earlier I used to find out about sheet wastage only at the end of the job — when it was too late to do anything about it."
The complexity — what makes rigid boxes different
Unlike a simple print job, a rigid box requires multiple components to be produced simultaneously, each going through its own sequence of stages before being assembled together at the end.
Top Label
Job docket → Paper → Printing → Lamination → Foiling → Embossing → Factory inward
Bottom Label
Job docket → Paper → Printing → Lamination → Factory inward
Boards
Job docket → Cutting → Scoring → Factory inward
Tray
Job docket → Cutting → Forming → Factory inward
Accessories
Procurement → QC → Factory inward
All 5 components complete → Pasting & Assembly → QC → Dispatch
Before Clicarity, tracking all five paths simultaneously under one job was either impossible or required a coordinator spending most of their day managing it manually. The wastage from each path was invisible until month-end reconciliation.
The solution
HC Boxes implemented Clicarity to move beyond general job tracking and into component-level management. By assigning each component its own sub-path under a single Job ID, the system created a transparent map of the entire factory floor — for every job, at every moment.
One Job ID — five component sub-paths
Each component of a rigid box job is assigned its own tracked sub-path under the parent Job ID. Top label, bottom label, boards, tray, and accessories each move through their own sequence of stages — independently, simultaneously, all visible under one job.
Quantitative logging at every handover point
At every stage, the system captures quantity in, quantity out, and wastage. Every handover point is a data point. The balance — how much is pending, in-process, and lost — is calculated automatically.
Real-time leakage detection
Wastage is visible by stage while the job is still running. The dashboard shows exactly where material loss is occurring — not at month-end, but right now, while there is still time to intervene.
Automatic reconciliation
The system calculates the remaining balance automatically at each stage, eliminating manual counting errors. When all components complete their paths, the system reassembles the data and continues tracking the finished unit through packing and dispatch.
Decentralised updates — shop floor owns their data
Shop floor teams update their own progress independently, removing the dependency on supervisors to report. Each person updates only their stage — and the full picture builds automatically for management.
What the data looks like
Here is an example of what Uday sees on his dashboard for a single rigid box job — while the job is still in production:
Before and after
Wastage invisible until job-end
Material loss across five components and multiple stages was impossible to attribute. Total loss only visible at month-end reconciliation — too late to act on it.
Wastage visible at every stage — live
Every stage captures quantity in, out, and lost. Loss is visible by component, by stage, while the job is still running. Management can intervene before the job is complete.
No component-level accountability
Without data showing which stage on which component caused the loss, no one could be held accountable. The same problem repeated every month.
Sheet-level visibility across every component
Every component has a complete, timestamped production trail. Patterns become visible across jobs — the same stage causing loss is identified and addressed.
The results
The implementation provided sheet-level visibility across every component. By identifying wastage patterns with numbers rather than guesswork, HC Boxes simplified its entire operation. The shop floor team transitioned to the digital system with zero retraining. The management gained the ability to intervene in production while jobs were still active — significantly protecting margins.
"Now I can see at which stage the loss is happening while the job is still running. That alone has changed how I manage production."
About HC Boxes
Hrimkar Creations (HC Boxes) is a Mumbai-based rigid box manufacturer producing premium packaging including gift boxes, luxury retail packaging, and custom rigid boxes for brands across India. The business handles complex multi-component jobs requiring simultaneous tracking of up to six separate production paths per order.
Uday Vora represents a generation of packaging manufacturers navigating the transition from manual tracking to digital visibility — not by replacing their process, but by making it legible for the first time.
India's leading print & packaging industry magazine · 40,000+ readers · 350+ cities
Track every component. See every loss. While you can still act.
Book a free demo — we'll show you how component-level tracking works for your specific manufacturing process.