If your raw material consumption and finished bag count never quite match at the
end of the month, one or more of these five gaps is almost certainly the reason.
1
No Loom-Wise Wastage Tracking
You know your total monthly wastage. But do you know which loom is responsible for most of it?
In most factories, wastage is recorded as a single daily or monthly figure. When one loom starts producing weak fabric or running at lower efficiency, it gets buried in the total number and nobody catches it for weeks.
What it costs you: A single underperforming loom can account for 30 to 40% of your total monthly wastage without anyone noticing.
What to check: Can your team tell you the wastage percentage for each loom separately, right now, without manually going through registers?
2
Tape Line Output Not Matched to Loom Consumption
The tape extrusion line produces a certain weight of tape every shift. The looms consume a certain weight of tape every shift. In most factories, these two numbers are recorded in separate registers and never compared in real time.
When tape output and loom consumption are not matched daily, excess tape gets misplaced, damaged, or written off without anyone understanding why.
What it costs you: Untracked tape movement between extrusion and weaving is one of the most common sources of unexplained raw material loss.
What to check: Does your system automatically match tape produced versus tape consumed every shift, or does someone have to do this manually at month end?
3
Shift-Wise Rejection Not Recorded at the Machine
Most factories record rejections at the end of the day or after quality checking. By then, the shift that caused the problem has already ended and the operator has gone home.
Without shift-wise rejection data at the machine level, the same quality problem can repeat across multiple shifts before anyone connects the dots.
What it costs you: Repeated rejections from the same loom or the same shift pattern that could have been caught and fixed within hours.
What to check: Can your team tell you which shift produced the most rejections last week, by loom, without searching through multiple registers?
4
No Real-Time Raw Material Stock Visibility
In most polysack factories, the stores team maintains a separate register for PP granule stock. The production team maintains a separate register for daily consumption. These two are reconciled at the end of the week or month.
In between, production runs without knowing exactly how much raw material is actually available. This leads to either over-ordering, which ties up working capital, or running short mid-production, which causes costly stoppages.
What it costs you: Production stoppages, emergency purchases at higher prices, and excess stock that sits in the warehouse and ties up cash.
What to check: Does your production team know the exact granule stock available right now, or do they have to check with stores every time?
5
Machine Maintenance Not Linked to Production Data
Loom maintenance is typically tracked in a separate register, often filled in manually after the service is done. Production data is tracked in another register. The two are never connected.
This means there is no way to see whether a dip in loom output or a spike in rejections happened around the same time as a missed or delayed maintenance cycle.
What it costs you: Unexpected breakdowns, higher rejection rates from poorly maintained looms, and repair costs that could have been avoided with earlier intervention.
What to check: Can your team pull up the maintenance history of a specific loom alongside its production and rejection data for the last 30 days?
How Many Red Flags Did You Find?
0–1
Your floor data is in good shape. A few small improvements could still save you money.
2–3
There are real gaps costing you money every month. Worth a conversation.
4–5
Significant wastage is happening that your current system is not catching. This is fixable.
Close the Gaps. Keep Working the Way You Already Do.
TCB Infotech helps polysack manufacturers close these gaps with a simple digital floor tracking system. No disruption to how your team works. Just better data, automatically.
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