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The challenge

When Asian Paints, India’s largest paint manufacturer, commissioned its new Khandala plant, factory automation was a key focus area of the plant design. But even the fastest machines and quickest changeover processes do not necessarily guarantee optimised production line volume.  

The team in the packing material warehouse was facing repetitive minor stoppages in the bulk filling line de-palletiser.

This impacted productivity in the water-based paint packing block due to the unavailability of pails on the high-speed packing line.

Forklifts were employed to deliver the packing material (PM) from the adjacent warehouse directly to the line. This resulted in a large number of forklift movements to supply pallets of pails to the denesting teams, and to manage the returnable packaging, all in the limited space between lines.

Despite a workaround, daily downtime on the bulk line averaged around 450 minutes per shift, which affected the factory service levels. To compound matters, the machine vendor was based in the US, which made on-site support prohibitively expensive. The technical team realised they had to address the problem on their own.



Asian Paints Limited is India’s largest paint company and Asia’s third largest paint company. Headquartered in Mumbai, Maharashtra, the company is engaged in the business of manufacturing, selling and distribution of paints, coatings, products related to home decor, bath fittings and providing of related services. It has operations in over 20 countries and has over 30 manufacturing facilities, servicing consumers in more than 65 countries.

Through a dedicated focus on improvement, unwavering management support and teamwork, combined with engineering ingenuity, Asian Paints transformed a complex production floor challenge into a major gain.

50%+ improvement of downtime on the bulk line

Reduced dependence on overseas-based OEM

Established systems to sustain improvement

Daily problem-solving capability established

Loss and waste analysis capability established

From our client

“TRACC’s integrated approach to manufacturing excellence and focus on engaging everyone in the pursuit of excellence has really helped us to percolate, accelerate and sustain our continuous improvement journey.”

Harish Lade, Vice President Supply Chain

From our client

“The TRACC-defined approach and process encourages one to deeply analyse each issue and validate its real existence. It helps negate the need for further capex, a typical approach that companies take towards de-bottlenecking. Establishing systems that help sustain the improvement is really a huge plus that TRACC provides.”

Mr Narasimhan K, former General Works Manager at the Khandala plant

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