Digital Transformation for Meghmani Finechem Ltd. (A Leading Chlor-Alkali Manufacturer)
Meghmani Finechem Limited (MFL), a flagship company of the Meghmani Group, is a prominent Indian manufacturer of chlor-alkali products, CPVC resins, caustic soda, and hydrogen peroxide. With a sprawling facility and complex logistics network, MFL embarked on a digital transformation journey to eliminate inefficiencies in manual gate and weighbridge operations.
“Manual gate processes caused truck delays, missed records, and lack of visibility. We needed a solution that could unify and digitize our entire flow—from raw materials to finished goods.”
– Head of Plant Operations
The Operational Challenge
Despite using an unmanned weighbridge system (previously implemented), the company faced challenges due to multiple (6–7) gates across its large facility, each serving a unique function (inbound material, outbound goods, internal movement, etc.). The main entry gate involved a manual QC checklist and document verification process, leading to inconsistent checks, data gaps, and avoidable delays. Raw material tracking, finished goods dispatch, and internal transfers were all handled manually or via disconnected systems.
This fragmentation created:
- Inconsistent entry protocols and delayed truck processing
- Inefficient coordination between gates and departments
- Lack of real-time visibility into material movement
- Errors in weighment and documentation not syncing with SAP
- Increased manpower dependency and compliance risks
The Smart Automation Solution
To address these issues, we implemented a comprehensive Gate Management Solution tailored to the client’s specific operational setup. The solution was designed to bring digital uniformity across all gates and integrate seamlessly with their existing unmanned weighbridge system and SAP.
The Smart Automation Solution
- Automated gate pass and checklist verification at the main gate
- Integration with unmanned weighbridges to capture weights in real-time
- Smart truck dispatch scheduling to avoid congestion
- Weight tolerance validation to prevent SAP-entry mismatches
- Live tracking of raw materials, finished goods, and internal transfers
- Consolidated dashboard for plant-wide logistics visibility and audit trai
Since implementing the Gate Management Solution, the company has seen tangible improvements across key operational metrics:
- Faster truck processing at all gates, reducing waiting time and manual paperwork
- Improved compliance with digital checklists and audit logs
- Zero weight mismatches thanks to automated SAP syncing
- Real-time data visibility for all stakeholders, enabling faster decision-making
- Enhanced operational coordination between logistics, QC, and production teams
Measurable Outcomes after digitisation
Operational Improvements
- Truck processing time reduced from 45 to 9 minutes (80% improvement)
- Weighment errors decreased from 7% to 0.2%
- 100% elimination of manual SAP entries
Strategic Benefits
- Complete digital audit trail for compliance
- Real-time dashboard for logistics monitoring
- Scalable architecture for plant expansion
" The automated gate system has transformed our operations. We’ve achieved efficient data synchronization across platforms, and material reconciliation errors have reduced significantly. Faster processing times have also strengthened our supplier partnerships. This digital leap sets a new standard for operational excellence in our industry"
