The company faced significant operational inefficiencies due to manual production reporting, which relied on labor-intensive check sheets and delayed issue identification. The lack of real-time reporting and absence of visual control boards led to bottlenecks, system disorganization, and communication gaps, making it difficult for management to monitor production effectively. To address these challenges, a web-based reporting system was developed, digitalizing the Bill of Materials (BOM) and automating data entry, inventory tracking, and production issue reporting. This solution enabled real-time monitoring, eliminating the need for manual data compilation and improving response times to production problems.
The implementation of the Digital Lean system resulted in significant efficiency gains and cost savings. By reducing manual data entry and improving process visibility, the company saved approximately RM75,000 annually in labor costs. Additionally, better inventory control through BOM tracking minimized material wastage, leading to an estimated RM50,000 reduction in excess material costs. The system also shortened production reporting time from hours to minutes, allowing quicker decision-making and preventing delays that previously impacted output. With these improvements, the company is now positioned to expand the digitalization initiative across all its facilities, further driving productivity and cost efficiency.
