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IND-PLASTICS-001
IND-PLASTICS-001
Plastics Processing & Household Products
Injection-moulded and blow-moulded consumer products where resin prices, scrap, mould cycle time, machine uptime and distribution cost decide margins.
Typical business challenges
- Resin (PP / HDPE) price volatility and late pass-through to customers
- Scrap, warping and colour variation on specific moulds and machines
- Cycle-time drift from mould cooling and maintenance gaps
- Slow-moving finished goods across a wide SKU range
- Freight cost and OTIF pressure from modern trade and distributors
Relevant financial indicators
- Scrap rate % by machine and mould
- Cycle time vs standard
- OEE and downtime
- Resin purchase price variance
- OTIF and backorders
- Freight per unit
- Forecast accuracy by category
Common operational bottlenecks
- Constraint moulding machines with high downtime
- Changeovers for colour and mould
- Single-source masterbatch suppliers
- Dispatch backlog at month end
Example improvement opportunities
- Scrap Pareto by mould and resin lot (DMAIC)
- Cycle-time reduction on high-volume moulds
- Resin index-linked pricing with key customers
- SKU rationalisation of slow movers
- Truck-fill and route optimisation
Examples only. Whether they apply to your business depends on your data.
Applicable supporting schedules
In addition to the Balance Sheet, P&L and Cash Flow Statement| Template | Name | What it shows |
|---|---|---|
| SCH-MAT-001 | Raw material consumption | Opening stock + purchases − closing stock = consumption, by key material. Total consumption should agree to cost of materials consumed. |
| SCH-WC-003 | Inventory by category | Year-end inventory by category. Total should agree to the Balance Sheet. |
| FN-MST-001 | Product Master (SKU list) | One row per product (SKU). Codes entered here are used to check product references in production, sales, dispatch and quality registers. |
| FN-PUR-001 | Purchase Order & Supplier Delivery Register | One row per purchase order line: supplier, material, quantity, price, promised and actual receipt dates, rejection and buyer. |
| FN-PRD-001 | Production Plan vs Actual Register | One row per production plan line (product × machine × shift × day): planned, actual, good and scrap quantity, cycle time, planned hours, downtime and changeover. |
| FN-STR-001 | Raw Material, WIP & Stores Stock Register | Stock movements by material and lot: opening, receipts, issues, returns, closing, reorder level, ageing, QC and count variance. Unit cost enables valuation of slow-moving stock. |
| FN-WHS-001 | Finished Goods Dispatch & Delivery Register | One row per dispatch line: customer, order, product, ordered and dispatched quantity, backorder, freight, promised and actual delivery, POD and returns. |
| FN-SAL-001 | Sales, Forecast & Customer Register | Monthly sales by customer, channel and product: units, net sales, discount, gross margin %, forecast units, open orders and complaints. |
| FN-QM-001 | Quality, Complaints & Maintenance Log | In-process and customer quality issues, rejections, complaints (with closure date), breakdowns and preventive-maintenance compliance. |
Request a plastics processing & household products assessment
We will confirm which schedules apply before you upload anything.
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