Case Study India’s Foremost Heavy Machinery Manufacturer Achieves 96% On-Time Delivery Through Digital Transformation
In-plant logistics plays a vital role in ensuring smooth operations within manufacturing facilities, where the flow of materials
Since its establishment in 1956, Kejriwal Castings Limited has become a leading name in India for Ductile Iron Socket & Spigot Pipes and Ductile Iron / Cast Iron Fittings, Flanged Pipes and Valves. The company is dedicated to producing high-quality products consistently and on time, ensuring customer satisfaction across all its offerings.
The company operates two state-of-the-art manufacturing facilities located in Durgapur and Chamrail, India. Today, with operations and supply chains spanning across 40+ countries and serving 15000+ customers globally, Kejriwal Castings stands as a prominent player in the water and sanitation field with an extensive product range that includes pipes, fittings, valves, manhole covers, maintenance items, and accessories.
Freight Costs Savings
On-time Vehicle Placement
Time Reduction in Freight Sourcing
Visibility and Collaboration
Improved Productivity
Audit Complaint
Despite Kejriwal Castings' large production capacity, the logistics team struggled with manually sourcing vehicles, which hindered their ability to secure enough vehicles to match production demands and impacted sales.
Previously, manually reaching out to 3-4 transporters via WhatsApp, email, and phone calls significantly extended the vehicle finalization time, led to higher freight costs and decreased employee productivity.
Limited visibility in the gate-in/gate-out process at the Durgapur and Chamrail plants posed a significant challenge. Relying solely on transporter-provided information and timestamps proved inefficient, resulting in increased plant congestion and detention expenses.
Ensuring on-time delivery of goods to customers was critical for them. However, reliance on transporters and manual tracking for details of each vehicle daily across multiple locations increased inefficiencies.
Managing physical POD copies from transporters and undergoing manual verification often led to confusion and inefficiencies. The physical copies were frequently circulated from one place to another, increasing the risk of errors, and delays in the verification process.
Lack of comprehensive visibility in the logistics operation, from initial freight sourcing to final bill settlement, caused transparency issues for the management regarding on-ground activities and decision-making processes.
Implementing the Freight Sourcing solution, Kejriwal Castings now secures vehicles in just 15 minutes, saving 50% of their time. This efficiency allows the plant to steadily increase vehicle sourcing each month, fully utilizing production capacity, handling dispatch constraints, and ultimately driving more sales.
Digitizing the Freight Sourcing process broadened their transporter network to over 15, achieving a remarkable 75% on-time vehicle placement and reducing freight costs by 7%, ultimately amplifying employee productivity.
Implementing SP In-plant Logistics solutions streamlined gate-in/gate-out with real-time visibility and control. Automated gate pass generation, and vehicle inspection, reduced congestion and detention costs.
Effortless tracking of 350+ shipments/month on a single screen reduced manual coordination. Real-time visibility, automated alerts, and ETA improve material delivery. This visibility facilitated proactive issue resolution and stakeholder collaboration for smoother operations.
SuperProcure's e-POD solution streamlined the invoice generation process, ensuring ease and accuracy. Additionally, it provided a comprehensive record where any incidences of damages or shortages were promptly documented, enhancing transparency and accountability.
Preset reports & dashboards provided insightful data on freight trends & transporter participation, which gave the management team 100% transparency of the ground-level activities.
At SuperProcure, we offer an end-to-end integrated solution for all your logistics needs. We are one of the leading logistics and supply chain management solution providers in India for manufacturing and infrastructure companies.
Our industry-recognized solutions include Freight Sourcing, Indenting Allocation, In-plant Logistics, Shipment Tracking, and Freight Accounting. These help resolve critical industry challenges associated with logistics and supply chain management.
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