Zventory’s AI-powered solution helped a printing & packaging unit enhance order accuracy, speed up production, and ensure on-time delivery.

Improving Order Accuracy, Production Speed & On-Time Delivery for a Printing & Packaging Manufacturer Using the Zventory (AI Powered)

Industry: Printing, Packaging, Corrugated Boxes, Labels, Cartons

Company Size: Mid-large scale, 2 factories & 120+ workforce

Modules Used: Inventory, Production, Sales, Purchase, Dispatch, DMS, QC, HR

Key Challenges: Order versioning, production scheduling, material wastage, dispatch delays, artwork control

Background

A printing and packaging company producing corrugated boxes, laminated pouches, product labels, mono cartons, and premium printed packaging faced operational difficulties as their customer base grew. With two manufacturing plants, 40+ machines, and multiple custom orders per day, their previous system (mostly Excel and manual job cards) was insufficient.

• Printing (offset/flexo/digital)
• Lamination
• Die-cutting
• Pasting
• Finishing
• Packaging & dispatch
• Multiple artwork, paper, and color variations per order

Rising rework, wastage, and missed deadlines led the company to implement the Zventory (AI Powered) to unify processes and eliminate bottlenecks.

The Challenges

1. Frequent Design/Artwork Modifications

Packaging orders often changed due to:

• Updated artwork
• New brand guidelines
• Altered text or barcode
• Different print finishes

Without proper control:

• Teams used wrong artwork versions
• Reprints increased production cost
• Customer dissatisfaction rose

2. No Real-Time Production Status

Production stages included:

• Artwork approval
• Plate making
• Printing
• Lamination
• Die cutting
• Pasting
• Packing

Manual tracking caused:

• Delayed updates
• Shift confusion
• Undetected bottlenecks
• Missed deadlines

3. Material Wastage & Incorrect Issuance

Materials like paper reels, ink, adhesives, laminates, and boards were often:

• Issued without tracking
• Wrong GSM or board grade used
• Over-consumed without visibility

4. No Accurate Cost Estimation

Without BOM and consumption insights:

• Costing approximated
• Customer quotations inaccurate
• Margins unpredictable

5. Dispatch Delays & Incorrect Deliveries

Finished goods tracking was unclear:

• No link between production completion & dispatch
• Batch-level traceability missing
• Real-time dispatch planning absent

6. Purchase Planning Was Unpredictable

Purchasing teams lacked:

• Updated consumption data
• Material requirement forecasts
• Stock visibility across warehouses

The Solution Implemented

The company implemented the Zventory (AI Powered) to automate processes, improve accuracy, and gain real-time visibility.

✔ Version-Controlled Artwork & Document Management

• Artwork versions, technical specifications, die-line files
• QC checklists, customer approvals
• Automatic notifications to relevant teams
• Only latest approved artwork used, eliminating reprints

✔ Advanced Production Workflow Tracking

• Start, Running, Pending, Finished Production stages
• Real-time supervisor updates
• Job visibility per machine & shift
• Bottleneck identification & productivity tracking

✔ Digital BOM & Material Requirement Planning

• BOM includes paper GSM/size, ink color/quantity, lamination, die-cutting tools, adhesives
• ERP checks raw material availability & historical consumption
• Prevents overconsumption & improves planning

✔ Batch-wise Material & Finished Goods Tracking

• Paper reels, ink lots, laminates
• Finished packaging products tracked from purchase to dispatch

✔ Auto Purchase Indent & AI Forecasting

• ERP triggers automated indents based on order load & consumption trends
• Predicts shortages, avoids emergency procurement

✔ Dispatch Automation

• Auto-dispatch list creation
• Vehicle allocation & customer notifications
• Batch-wise delivery records

✔ QC Integration

• Print quality, color match, GSM, lamination bonding, die-cut alignment
• All QC results logged digitally and linked to jobs

The Results

1. 50% Reduction in Reprints & Rework

2. Production Speed Increased by 35%

3. 30% Reduction in Raw Material Wastage

4. Accurate Job Costing

5. Dispatch Accuracy Reached 99%

6. Purchase Planning Became 45% More Efficient

7. Improved Customer Trust & Repeat Orders

Conclusion

The Zventory (AI Powered) transformed the printing and packaging company into a highly efficient, technology-driven manufacturer. Integrating artwork management, production workflow, BOM planning, QC, dispatch, and purchase automation achieved faster production cycles, lower wastage, higher accuracy, better costing control, and stronger customer satisfaction—enabling confident scale-up and consistent quality.