Chazlytics
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04 / Production, processing and packaging

See what is holding production back.

A batch can be ready while filling waits for bottles. Containers can be ready while the product is still being processed. Follow both sides, from raw materials to packed goods, to see what was made and where work is waiting.

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How this part connects

Two streams meet at filling.

Goods / work
Two streams meet at filling.Product processing and packaging manufacture run side by side. They meet at filling, then the goods are sealed, packed and prepared for dispatch. The full process shows how bottles, buckets and caps are made, as well as packaging bought from suppliers. Product processing Packaging manufacture Filling and packing Finished goods Distribution Two streams meet at filling.Product processing and packaging manufacture run side by side. They meet at filling, then the goods are sealed, packed and prepared for dispatch. The full process shows how bottles, buckets and caps are made, as well as packaging bought from suppliers. Product processing Packaging manufacture Filling and packing Finished goods Distribution

Product processing and packaging manufacture run side by side. They meet at filling, then the goods are sealed, packed and prepared for dispatch. The full process shows how bottles, buckets and caps are made, as well as packaging bought from suppliers.

Illustrative process.

Explore the full process
01

Find the stage that is waiting

Look at the product batch, available containers and filling output together. Is filling waiting for the product, the packaging or a machine to restart? Start with the stage that needs attention.

02

Account for the materials used

Compare the material sent to a job with the good output, rejected items and scrap. For bottle production, follow the plastic resin through preforms to finished bottles. Use matching units when comparing quantities.

03

Follow a batch through to dispatch

Keep the batch, quality checks and packing records together. When a question comes back from stores or distribution, trace the finished goods to the work that produced them.

Full process: Production, processing and packaging

Two manufacturing streams. One finished product.

Operation flowRecords to compare
Two manufacturing streams. One finished product.Illustrative manufacturing flow. Product inputs pass through processing and quality checks before release for filling. Packaging is made alongside the product, ready for the two to meet. PET resin passes through injection moulding to make preforms. A preform is the moulded starting shape that is later blown into a bottle. Stretch blow moulding turns those preforms into finished bottles. Buckets and caps follow separate injection-moulding paths. Injection-moulding machines or presses and blow-moulding machines use moulds as tooling: the mould gives the item its shape. It is not a separate machine. Product and containers meet at filling. Closures join at sealing or capping, followed by labelling and packing. Bought-in containers, closures, labels and cartons remain an additional supply. Compare materials supplied with good output, rejects and scrap using matching units. This explains yield: the usable output from the material supplied. Review quality checks, machine runs, energy use and downtime to understand where work is waiting. Product streamPackaging manufacture · three separate paths Product inputs Raw materials issued Processing Product line and batch Product quality Checks and release Ready for filling Released product PET resin Pellets / granules Injection moulding Machine + preform mould PET preforms Manufactured in-house Stretch blow moulding Blow machine + mould Bottles Container output Plastic resin For buckets / pails Injection moulding Machine + bucket mould Buckets / pails Separate container path Plastic resin For caps / closures Injection moulding Machine + closure mould Caps / closures Join at sealing / capping Bought-in containers Additional supply path Filling Product + containers Sealing / capping Filled goods + closures Bought-in supplies Labels and cartons Labelling and packing Prepare finished goods Finished goods Stock ready to move Dispatch / distribution Loads and deliveries Check quality and output before fillingResin issued and outputRejects / scrapMould and machine runsEnergy and downtime

Product stream

  1. Product inputsRaw materials issued
  2. ProcessingProduct line and batch
  3. Product qualityChecks and release
  4. Ready for fillingReleased product

Released product joins containers at filling.

Packaging manufacture: PET bottles

  1. PET resinPellets / granules
  2. Injection mouldingMachine + preform mould
  3. PET preformsManufactured in-house
  4. Stretch blow mouldingBlow machine + mould
  5. BottlesContainer output

Bottles go to filling. Preforms belong only to this PET bottle path.

Packaging manufacture: buckets / pails

  1. Plastic resinFor buckets / pails
  2. Injection mouldingMachine + bucket mould
  3. Buckets / pailsSeparate container path

Buckets go to filling on a separate path.

Packaging manufacture: caps / closures

  1. Plastic resinFor caps / closures
  2. Injection mouldingMachine + closure mould
  3. Caps / closuresJoin at sealing / capping

Closures join the filled containers at sealing / capping.

Additional bought-in supply

  1. Bought-in containersAdditional supply path
  2. Bought-in suppliesLabels and cartons

Bought-in containers join filling; labels and cartons join labelling and packing.

The streams come together

  1. FillingProduct + containers
  2. Sealing / cappingFilled goods + closures
  3. Labelling and packingPrepare finished goods
  4. Finished goodsStock ready to move
  5. Dispatch / distributionLoads and deliveries

Product and container manufacture meet at filling, then move towards distribution.

Check quality and output before filling
Resin issued and outputRejects / scrapMould and machine runsEnergy and downtime

Illustrative manufacturing flow. Product inputs pass through processing and quality checks before release for filling. Packaging is made alongside the product, ready for the two to meet.

PET resin passes through injection moulding to make preforms. A preform is the moulded starting shape that is later blown into a bottle. Stretch blow moulding turns those preforms into finished bottles. Buckets and caps follow separate injection-moulding paths.

Injection-moulding machines or presses and blow-moulding machines use moulds as tooling: the mould gives the item its shape. It is not a separate machine.

Product and containers meet at filling. Closures join at sealing or capping, followed by labelling and packing. Bought-in containers, closures, labels and cartons remain an additional supply.

Compare materials supplied with good output, rejects and scrap using matching units. This explains yield: the usable output from the material supplied. Review quality checks, machine runs, energy use and downtime to understand where work is waiting.

Across departments

How this connects to the rest of your business

Materials for the job

See what stores supplied for the product and its packaging, including bought-in containers, closures, labels and cartons.

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Power for the line

Look at electricity use and power cuts alongside machine runs, container output and finished goods.

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Goods ready to leave

Follow the finished goods from release to the load leaving the gate.

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See these connections on the full operation map

When output falls short, can you see which stage needs attention?

Bring a question your team needs to answer. We will walk through the work and the records with you.

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