Plastic Industry – Cost

Clearly Manage The Costs from Materials & Production Feedbacks

Regrind materials and production efficiency are the important factors that may affect the plastic industry cost reduction. If regrind materials’s inventory didn’t well managed, taken by the site worker on visual judgment will cause the regrind materials usage inaccurate compare to the system’s material inventory. Production scheduling by manually unable to fulfill the different complex requirement of multiple continuous batch (Item No, Mold, Machine, Color…etc.), causes the frequent change of mold and low OEE.

The improvement of profits in the industry starts from the competitiveness advantages in details!

Regrind Materials Cost

Work Hour Cost

Cost Management

Regrind Materials Cost

Common Issue

Large differences in the inventory stock check every month end, what are reasonable effective ways

Store Management

Plastic and regrind materials are used by site worker flexibly, but system material only reduce according to the standard usage, it is not correspond to the actual usage, causing inventory inaccurate

Cost Accountant

Production Material Usage cost distortion, causing the cost of materials fluctuated, financial statements and profit analysis have lots of questionable issue. 

General Management

Inaccurate cost of production materials will impact cost analysis and operation decision-making analysis

Solution Plan

Regrind Materials Cost solution plan

Regrind Materials Cost solution plan

Work Hour Cost

Common Issue

Need to collect production work hour, but unable to execute collection sometimes due to occupied or unavailable, only able to record down the minutes after work by memories.

Site Worker Manager

Factory site didn’t have the tools to collect or instant feedback on the work hour minutes. In result, the work hours minutes cannot be collected correctly and immediately.

Cost Accountant

Every month the work hour reporting are slow and inconsistent compare to the worker’s attendance How will the cost will accurate when the work hour is inaccurate.

Solution Plan

Work Hour Cost solution plan

Cost Control

Common Issue

Stock-Out Note input data complicated (Item No/ Serial No/ Lot No/ Effective Date). Error data record will happen easily when not being careful, there will be trouble if the factory auditor found out data differences.

If barcodes cannot be apply to simplify the efficiency and accuracy of in out shipments and inventory, it may affect customer satisfaction with the quality of the shipment

Site Management

Production scheduling by manually unable to fulfill the different complex requirement of multiple continuous batch (Item No, Mold, Machine, Color…etc.), causes the frequent change of mold, idle and standby man power, unable to fully utilize production capacity and low OEE.

Production Management

There are no effective production scheduling method, incapable of arranging the most efficient manpower layout, causing the production facing stagnation

Solution Plan

Cost control solution plan

Cost control solution plan

Industry Case Studies

DEE NOON CORPORATION SDN BHD – ERP IMPLEMENTATION

DEE NOON CORPORATION SDN BHD – ERP IMPLEMENTATION

From left: Ms Jasmine Kang (Project manager), Ms Lok Kah Mun (ERP Project Manager), Mr Kang (Director of Dee Noon), Ms Khor (Project manager) Dee Noon Corporation Sdn Bhd (Dee Noon) was established on May 2006. Managing director of Dee Noon, Mr Kang and his team...

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