Fast-Moving Consumer Goods (FMCG)

Industry Snapshot

FMCG plants juggle volatile demand, small SKU lots, and strict food-safety standards. Changeovers, packaging waste, and energy use are primary cost drains.

Pain Table

Source of Waste	Business Impact
Frequent SKU changeovers	OEE dips, overtime
Packaging defects & leaks	Market returns, brand damage
Energy-intensive utilities	Operating costs ↑

Solution Menu

Operational Efficiency Drive – SMED on form-fill-seal, TPM on utilities.
Process Transformation – arcode traceability and dynamic scheduling.
Six Sigma Culture – projects on net-content fill variance and packaging leaks.
Financial Governance – ABC costing by SKU, channel, and promo.

Capability Courses

Drive Highlight

Fill-Weight Accuracy Drive – five Green-Belt projects cutting giveaway by 1.5 g per sachet, saving ₹1.8 crore annually.

Targeted FAQs

Will lean conflict with FSSAI audits?

Visual controls actually simplify GMP compliance checks.

How fast can we see SMED benefits?

30 % changeover-time cuts are common within four weeks.

What energy savings are realistic?

TPM on compressors and boilers typically yields 8–12 % kWh reduction.

Can traceability work offline?

Yes—handheld barcode scanners sync when the network is restored.

How to manage SKU proliferation?

Dynamic scheduling and ABC analysis highlight low-margin SKUs to prune.

Do operators need statistical skills?

Visual SPC charts allow shopfloor teams to spot trends without complex math.