🇮🇳India

बैच ट्रैकिंग विफलता से गुणवत्ता रीवर्क और क्षति

3 verified sources

Definition

Manual batch records delay root-cause identification. A defect traced to 'Batch B-2025-001' may require rework of 3–4 adjacent batches if traceability links are weak. Customers file compensation claims or reject shipments.

Key Findings

  • Financial Impact: ₹50,000–₹500,000/defect incident (rework labor + materials + customer credit); typical firm experiences 2–4 incidents/year = ₹100,000–₹2,000,000/year
  • Frequency: 2–4 quality incidents annually; rework spans 15–30 days per incident
  • Root Cause: Manual batch record keeping; poor equipment integration; delayed deviation logging

Why This Matters

The Pitch: Indian clay/refractory plants lose 2–5% of revenue annually to rework, customer refunds, and warranty claims due to inability to isolate defective batches. Automated batch traceability reduces rework by 60–80%.

Affected Stakeholders

QA, Production, Customer Service, Accounts

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Financial Impact

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Current Workarounds

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Methodology & Sources

Data collected via OSINT from regulatory filings, industry audits, and verified case studies.

Evidence Sources:

Related Business Risks

GST बैच डॉक्यूमेंटेशन अनुपालन दंड

₹10,000–₹25,000 per audit observation; typical firm sees 4–8 flagged batches/quarter = ₹40,000–₹200,000/year

मैनुअल बैच ट्रैकिंग से उत्पादन बाधा और क्षमता हानि

30–40 hours/month × ₹500–750/hour (QA+admin labor) = ₹15,000–₹30,000/month = ₹1,80,000–₹3,60,000/year. Lost sales due to delayed shipment: ₹1,00,000–₹5,00,000/year (5–15% capacity loss)

बैच ट्रैकिंग अनुपालन सर्व और डुप्लिकेट परीक्षण लागत

Redundant testing: ₹200–400/test × 50–100 batches/month = ₹10,000–₹40,000/month = ₹1,20,000–₹4,80,000/year. Manual record maintenance: 15–25 hours/month × ₹400–600/hour = ₹6,000–₹15,000/month = ₹72,000–₹1,80,000/year. Compliance audit prep: ₹50,000–₹2,00,000/year.

बैच प्रमाणन में देरी से A/R (खातों प्राप्य) में वृद्धि और नकदी प्रवाह में खिंचाव

₹2,00,00,000 typical annual sales ÷ 365 = ₹54,794/day working capital × 5 days delay × 20% cost of capital (annual) ÷ 365 = ₹15,000–₹50,000/year (conservative). Larger firms: ₹5,00,00,000 sales → ₹50,000–₹2,00,000/year cost of delayed DSO.

बैच डेटा अदृश्यता से क्रय और उत्पादन निर्णय त्रुटि

20–30% of raw material waste × ₹50,00,000 annual raw material cost = ₹10,00,000–₹15,00,000/year preventable loss. Suboptimal supplier mix: 5–10% overpayment vs. best-in-class supplier = ₹25,00,000–₹50,00,000/year opportunity cost.

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