PVC Manufacturing Plant (Pune)

PVC Man plant in Pune ,80% capacity, 3 cycles/day, FOS=90

177MT per cycle so 3 cycles = 531 MT per day

Or 531*30 = 159300 monthly or 191160 MT yearly

Additionally, can you suggest the optimal number of reactors we can install in our PVC Plant if we
the ability to run multiple reactors simultaneously? Ans => one additional reactor

Sum of 48604 + 37390 + …. + 25632 = 191617 MT

Scope => efficiency of reactor / efficiency of tanks Ans => same efficiency to maintain cost

5 Toy Manufacturing Plants

( 60% capacity => 1MT to 50 toys)

So total MT received is 191617 MT and hence * 50 = 9580850

Noida Nagpur Bhubaneshwar Lucknow Rajkot

^This sum is 9580889 toys

1)
 our logistics team is always challenged with the overall costs whenever we take a longer
route to deliver toys. What do you think we should do?

2)

They satisfy demand for

wholesale distribution

Distribution stores (Customers pick toys from here)

Delhi Chennai Kolkata Goa Mum Jaipur Bhopal Shimla

^ ^11743184 (Demand more)

One thing I would like to point out is that many times we face shelf availability issues as we are not
able to replenish toys in our toy distribution centres, which in turn aren’t able to reach the retail
stores, leading to loss of sales.

Toys are sold at 500 a piece and rejected one at 50

Current State :

Sub standard , Mismanaged supply chain of toys to its distribution centres

No sops in place to generate additional revenue of rejected toys

Identification of addressable issues :

Under utilization of PVC manufacturing plant

Over staffed ~ Salaries

Lack of raw input materials due to lack of reactors

Lapse in demand of toys dist cent and supply of toy manu plants

Spending more in long routes (freight costs )

Solution

Addition of chain of C1 , E1 , D1 , M1 and WH1 along with extra reactor

Or

Same set up with increase capacity utilization of tanks and imp eff of equipments

2) Drop attrition rate based on staffing requirement

3) Waiting time reactor to be decreased by additional setup
4) Route cost analysis se freight cost decrease
5) Fix demand supply issue of toy manu and dist channel

Recommendations

1) Use of sops and best practices to improve overall structure

2) Market trends affecting toys segmentation
3) Scrap dealing to be adjusted according to peak season and not to be sold at flat 50
4)