Your Plan Is Ready. What Will Stop the Line?
Production planning and scheduling for personal hygiene and home-care manufacturing.
Choose What You Want to Check
Production Sequencing Board
“Given everything we need to produce, what should run first?”
Check every SKU for material, packaging, QA and line readiness. Compare your current plan with an improved production sequence.
Filling Line Bottleneck Finder
“Where is my filling line actually losing capacity?”
Enter your production hours, speed, downtime and waiting time. See which constraint is costing the line the most.
The Schedule Can Look Fine. The Shift Still Loses Hours.
Material, packaging or QA is still pending when the order reaches the line.
The same orders take longer because of the sequence they run in.
One material, component or approval turns scheduled production into waiting.
Move one SKU forward and the rest of the production plan moves with it.
The machine is running, but actual output is well below what the line should deliver.
Downtime, cleaning, material waiting and quality clearance quietly eat into available hours.
The first question is not always, “Do we need more capacity?”
It is: Where are the hours going?
The Tools Diagnose. The Shop Floor Proves What Is Possible.
Context: Productivity and inventory optimisation in an FMCG manufacturing environment.
The Tool Shows Where to Look. Gemba Works on What Is Behind It.
A readiness conflict may come from planning.
A long changeover may come from the way the sequence is built.
A slow filling line may come from speed loss, downtime, material waiting or a bottleneck at another stage.
Gemba works with the people running the plant to find the cause, implement the change and make sure the improvement holds.
Diagnose
Find where time and output are being lost.
Baseline
Put a number against the current condition.
Implement
Work with the team on the shop floor.
Sustain
Build the review system into daily operations.
Found Something Worth Fixing?
Bring the output from either diagnostic.
A manufacturing consultant can help you understand whether the issue sits in: