Zventory’s AI-powered solution enabled a plastic moulding & packaging manufacturer to gain real-time inventory visibility, optimize mold-based production planning, reduce material wastage and rejections, and seamlessly manage multi-warehouse stock movement across units.

Achieving Real-Time Inventory Control, Reducing Material Loss & Increasing Production Accuracy Using the Zventory (AI Powered)

Industry: Plastic Injection Moulding, Blow Moulding, Packaging Products

Company Size: 180+ employees, 3 manufacturing units

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

Key Challenges: Material wastage, mold-based production planning, stock mismatch, rejections, multi-warehouse movement

Background

A leading plastic moulding company manufacturing household plastic items, caps & closures, plastic bottles, packaging containers, and industrial moulded components faced operational challenges as production complexity increased.

• Granules & raw materials
• Color masterbatches
• Multiple moulds
• Machines with defined cycle times
• QC inspections
• Packaging readiness
• Multi-warehouse logistics

The company relied on semi-manual processes for material issuance, job planning, and stock updates. As order volumes grew, stock mismatches, production delays, and higher rejection rates began impacting performance.

To streamline and scale operations, the company implemented the Zventory (AI Powered).

The Challenges

1. Inconsistent Material Issuance & Tracking

Plastic moulding operations depend on raw polymer granules, additives, and color masterbatches. However:

• Material consumption was not recorded accurately
• Leftover material from machines was not tracked
• Color masterbatch wastage was high
• Incorrect materials were occasionally issued

2. Mould & Machine Scheduling Conflicts

Each product required a specific mould and machine combination. Manual scheduling resulted in:

• Improper job sequencing
• Idle machine hours
• Unexpected mould unavailability
• Unclear production priorities

3. High Rejection Rates

Product rejections occurred due to:

• Incorrect material mixing
• Improper temperature or pressure settings
• Lack of batch traceability
• Manual errors in recording machine parameters

4. Uncontrolled Stock Transfers Between Warehouses

With multiple warehouses and production units:

• Material transfers were not logged properly
• Finished goods movement lacked traceability
• Packaging materials were frequently misplaced

5. Limited Visibility into Production Output

Manual production logs made it difficult to track:

• Actual vs planned output
• Machine downtime
• Shift-wise performance
• Mould-wise production efficiency

6. Reactive Purchase Planning

The purchase team struggled due to:

• No real-time consumption visibility
• No automated reorder alerts
• No AI-based forecasting
• Unclear raw material requirements

The Solution Implemented

The Zventory (AI Powered) delivered complete digitalization across inventory, mould management, production, QC, purchase, and dispatch.

✔ Granule & Masterbatch Tracking

• Batch-wise granule tracking
• Accurate masterbatch consumption recording
• Correct material issuance to machines
• Mould-wise usage history

✔ Mould & Machine Mapping

• Product-to-mould mapping
• Machine capacity alignment
• Defined cycle times
• Hourly production output tracking

✔ Production Workflow Automation

• Start, running, pending, and finished production tracking
• Shift-wise production logging
• Machine downtime recording
• Mould maintenance reminders

✔ QC Process Integration

• Weight, color, and dimensional checks
• Surface finish inspection
• Batch-wise QC approval or rejection
• Rejected batches blocked from dispatch

✔ Stock Transfer with Full Traceability

• Raw material movement tracking
• Finished goods transfers
• Packaging material control
• Work-in-progress stock visibility

✔ Automated Purchase Indent & AI Forecasting

• Purchase indents based on real-time stock
• Consumption-rate analysis
• Production-driven material planning
• AI-based demand forecasting

✔ Dispatch & Packaging Coordination

• Production completion linked to dispatch
• Correct packaging material availability
• Batch-wise delivery traceability

The Results

1. 30% Reduction in Material Wastage

2. Production Efficiency Improved by 45%

3. Rejection Rates Dropped by 25%

4. Zero Stock Mismatch Across Warehouses

5. Purchase Planning Became 40% More Effective

6. Dispatch Accuracy Reached 98%

Conclusion

Zventory (AI Powered) significantly improved operational efficiency for the plastic moulding manufacturer. By connecting inventory, mould scheduling, production workflows, QC processes, purchase planning, and dispatch into one unified system, the company achieved higher output, reduced material wastage, consistent quality, faster dispatch cycles, and stronger customer satisfaction—positioning the business for long-term scalability and leadership.