Case Study: Asian Paints achieves 50% reduction in bulk line downtime with Competitive Capabilities International

Inspired quick-win PIP provides brighter hue for Asian Paints

Asian Paints, India's largest paint manufacturer, faced significant productivity challenges at its new Khandala plant. Repetitive minor stoppages at the de-palletiser on the bulk filling line were causing approximately 450 minutes of daily downtime per shift, impacting service levels. Competitive Capabilities International (CCI) was engaged to help address this issue using the TRACC continuous improvement solution.

CCI implemented a Focused Improvement TRACC program, training site teams in loss and waste analysis. A Profit Improvement Project (PIP) was launched to tackle the 'packing material in waiting' issue. Through direct observation, root cause analysis, and visual management, the team identified and resolved the core problems. As a result, Asian Paints achieved a 50% reduction in bulk line downtime, reduced dependence on the overseas OEM, and established systems to sustain the improvements and build daily problem-solving capabilities.

Asian Paints

Harish Lade

Vice President Supply Chain