Solution stories
FMCG Snacks: Multi-Plant Planning and One Trusted Number
Common masters, changeover planning and daily group visibility across plants.
Trikaan Research & Engineering4 min read
KEY TAKEAWAYS
- Five plants had five ways of counting output.
- Common masters came before dashboards.
- Changeover sequencing recovered capacity.
- Leadership got daily answers instead of a monthly pack.
A snacks manufacturer with several plants and hundreds of SKUs struggled with stock-outs in some regions and expiring stock in others.
Here is how the products fit together.
The situation
Each plant used its own codes and spreadsheets. Group reporting took over a week. Changeovers were sequenced by habit.
What they had already tried
- A BI dashboard on top of plant spreadsheets.
- Weekly calls with plant heads.
- Higher safety stock everywhere.
How we diagnosed the real problem
We compared definitions and codes across plants and timed changeovers.
- The same SKU had different codes across plants.
- Output was counted before or after QC depending on plant.
- Changeovers were a large share of lost time on packing lines.
The solution, product by product
No single product solved this. The value came from the products working on the same data.
| Product | Role in this solution |
|---|---|
| Anvaya | Common masters, plant stock, distributor orders, dispatch |
| ASTR Production | Line schedules with changeover matrix, plan vs actual |
| ASTR Reporting | Daily group view: service, stock cover, expiry risk, plant comparison |
| Machine Digital Twin | Packing line OEE and changeover times |
How it rolled out
- Master data harmonisation.
- Metric dictionary.
- Lighthouse plant.
- Template rollout to other plants.
What changed
Planners sequenced better and leadership trusted one number.
- Group reporting from days to daily.
- Changeover time reduced by [X]%.
- Expiry write-offs reduced by [X]%.
What we would tell a similar company
- Harmonise masters first.
- Agree metric definitions.
- Measure changeovers.
- Roll out by template.
Frequently asked questions
How long does master harmonisation take?
It depends on the number of SKUs and plants; plan it as its own workstream.
Can plants keep local practices?
Yes, on shared data.
Is this a real customer?
It is an illustrative composite.
- #FMCG manufacturing case study
- #multi-plant planning case
- #snacks manufacturing software
- #changeover optimisation
- #FMCG reporting
Trikaan Research & Engineering
Trikaan
Written by the researchers and engineers who build Anvaya, ASTR and Seed Track, with input from Trikaan's delivery and engineering teams.
