2.
Key issues 2020
Trending down profitabilitysince 2018 20.80%
Rising YOY costs(Cost to revenue %) 82.70%
High attrition rates 21%
Rejection resale rates 50
Utilization levels of PVC plant
Shelf availblity issues
Cost challenges in Longer Logistics route
High Rejection rates & QA SOP
close dependancy on Retail distribution levels
Inefficiencies in Supply Chain
Rise in Logistics costs
2019 2018 [Link] Setup Per day output
22.40% 28.50% PVC MANUFACTURING 531
81.16% 77.80% TOY MANUFACTURING
13% 12% DISTRIBUTION CENTRES
50 50
1.a PVC Input from Nagpur plant MT/PA
Noida 48604
Nagur 37390
Bhubaneshawar 60558
Lucknow 19433
Rajkot 25632
191617
1.b PVC To Toy Conv. No of Toys (PA)
Noida 3,892,080
Nagpur 1,847,652
Bhubaneshwar 1,542,520
Lucknow 979,709
Rajkot 1,318,928
9,580,889
1.c Dist. Centres No of Toys(PA)
Delhi 3,229,340
Chennai 880,737
Kolkata 1,321,168
Goa 440,389
Mumbai 4,110,034
Jaipur 587,172
Bhopal 587,214
Shimla 587,130
UOM Current Utilization No of Locations/cities
MT 80% 1
60% 6
8
Capacity (No of
% Utlization
Toys PA)
6486800
3079421
2570866
1632859
2198213
15,968,159 60%
26,271,540
13,718,821
34,706,691
15,871,292
32,940,222
123,508,566
12.35
3. Solution Creation
1)
a
b
c
d
2)
a
b
c
3)
4)
Revenue Streams
Expanding sales distribution channels via going for ecommerce platform(AMAZON, FLIPKART & OTHERS, exploring the opti
Customer segemenation based on the Income groups, New market trends to be explored.
Increasing the capacity of PVC reactor to 90% by adding a small reactor to increase the overall PVC output to 195 MT/day
Introducing AntiViral /Bacterial finishes on the our product offerings this can incentivise us to increase the prices to offset
Cost Heads
Manpower Rationalisation : in terms of standby personnel & shift engineers
Reducing the High QA rejections in few manufacturing locations, QA SOP establishments
Avoiding scrap selling at flat 50/Pc of defected toys and explore alernate vendors and exploring avenues of reycling defec
Organisation Policies
Need to look at the organisation structure & organisation policies to check for attrition
Hypothesis for Logistics
If Truck based, explore use of backward loading of empty truck
If train based, optimal usage of routes
Based on the Location lead times & freight rates , routes can be optimized . Routes can be fixed based on maufacturing loc
1MT : 50 Nos
797 Nos Extra Toy Pc made at 90 % A grade
398,250 added revenue at 500 /Pc
7 Crs PA revenue, extra
1 2
Freight Cost(In INR
at 90 % % Cap Util Toy Manufacturing Location Delhi Chennai
3,892,080 5 Noida 2 3
2,771,478 1,847,652 4 Nagpur 3 2
1,542,520 1 Bhubaneshwar 3 2
979,709 1 Lucknow 3 2
1,318,928 3 Rajkot 1 3
60%
3,229,340 880,737
Lead Times
Toy Manufacturing Location Delhi Chennai
Noida 1 2
Nagpur 2 4
Bhubaneshwar 3 3
Lucknow 4 5
Rajkot 5 2
2 3 4 1 1 2
Freight Cost(In INR /Toy)
Kolkata Goa Mumbai Jaipur Bhopal Shimla
1 1 2 2 2 1 1,685,951 short
2 3 2 3 1 1 3,363,346 short
1 2 1 3 3 3 -294,771 xcess
1 3 3 2 1 1 341,365 xcess
3 1 2 1 3 2 295,745 short
1,321,168 440,389 4,110,034 587,172 587,214 587,130
Lead Times
Kolkata Goa Mumbai Jaipur Bhopal Shimla
3 2 2 2 3 3
2 3 2 5 4 2
5 2 5 3 3 4
4 4 3 4 5 1
4 1 2 4 3 3