A.P.S. MullakandaGroup Chairman/Managing Director

MOUNT GROUP OF COMPANIES

APO International Productivity Showcase

& Best Practice Networking Forum on SMEs

Growth Strategy

Best Practices of

VISION

TO BECOME

THE NUMBER ONE LEADING COMPANY IN

PACKAGING INDUSTRY IN 2020

MOUNT PACKS (PVT) LTD.

MOUNT PRINTERS (PVT) LTD.

CAVALLO LEATHER PRODUCTS (PVT) LTD.

Corrugated Cartons Manufacturers

Offset Printing / Emboss, Plain UV & Lamination

Manufacturer of Genuine Leather Products

Best Practices

• Capturing new market segment with new products.

EVERY TIME WE DO REAL THING - REAL WAY - REAL TIME

• Apply productivity methods. (5s & Productivity tools)

• On time delivery.• Employee development.• Customer evaluation.

Last years we make “B” grade less production to limitedmarket area. But now we can give “A” grade most valueadded cartons to customers.

Before 2010

Limited capital

Limited floor capacity

Limited machines

Limited customer base

Weakness management system

Low productive machine arrangement

More customer complains

Our company had

That period our monthly production is very low. We couldn’t delivermany orders on time. And couldn’t continue good quality of cartons.

The“B” grade carton(box)

• Low strength

• Low print quality

• Low profit margin

• More man hours/More Time

• More machinery usage

• More waste

Before 5 years we couldn’t capture new market segments with this“B” grade box. But we give a best price to customers for thiscartons. There for we captured some market segment with oursmall machines and staff.

CHALLENGES

MARCH, 2010

Joined hand with “Kaizen Entrepreneurs” of National Productivity Secretariat.

• Trained all employees for productivity by NPS.

• Implement 5s, productivity tools & continue Kaizen.

• Trained “Kaizen Managers” by NPS.

• Implement “KIC Team” (Kaizen Implementation circle)

• Apply 5s & Productivity Methods

WE GOT CHANCES TO TRAIN FROM NPS & APO

We save

MORE money, MORE time, MORE man hours.

Construction

• Began Construction of “C” Building

& “D”.

AB

C

D

• Began Construction of “B” Building

• Bought a new land for Large

Expansion

Our Changes - Machines

PREVIOUS CURRENT

MAIN PLANT Flexo Printer

Single Facer 2 Ply Plant Fully Automated 5 ply PlantOne colour flexo printer 4 colour multi function Printer

CREASING MACHINE

Rotary Creasing Machine

Slotter DIE CUTTER

New Machines for Value Add

• Plain & Emboss Laminating Machine

• Plain & Emboss UV Varnish machine

• SORSZ Offset Printer

• KORD Offset Printer

• Cylinder Die Cutter

• Foiling Machine

Capturing New Market Segment with New Products.

PREVIOUS CURRENT NEW PRODUCT

* “B” grade box “A” grade Box

*Only duplex board print for inner box(outdoor)

Duplex Print (in house) with Emboss/plain UV, Emboss/plain lamination,Embossing, Foiling

*Flexo print for outer box

4 colour Offset & flexo print for outer box using duplex board, Test Liner, White Liner & Craft Liner paper.

• Purchased brand new fully automated machines to get Quality Product.

Now we can make International level Products.

Our New Products

Growth from 2009 to 2014

0 0 0 0 0 0

63,058,822

96,862,549

108,299,778

125,786,304

140,998,759

188,137,000

0

20000000

40000000

60000000

80000000

100000000

120000000

140000000

160000000

180000000

200000000

2009/2010 2010/2011 2011/2012 2012/2013 2013/2014 2014/2015

Annual Turnover

Growth from 2009 to 2014

0

20000000

40000000

60000000

80000000

100000000

120000000

140000000

160000000

180000000

200000000

2009/2010 2010/2011 2011/2012 2012/2013 2013/2014

Fixed Assets Value

19,924,034

41,800,358 50,939,049

147,494,122

175,129,123

On Time Delivery & Customer satisfaction

• Now we finished a job within 5 days. Urgent orders deliver in 3 days.

• Arrange the roots for 4 vehicles.

Before apply productivity method we cant estimate timefor a job. There for we couldn’t give a order at on time.

We evaluate customers every time for

o Customer satisfaction

o Give good service

o To increase the customer base

Sustainable Development

• Biomass boiler (Echo friendly, Cost effective, Foreign currency saving).

• Sound proof machines (Anti noise latest design machines)

• Using a natural lighting system for whole factory in day time.

• To be use LED bulbs for whole factory and office.

• To be installed solar panel system as a security lighting

• Rain water harvesting project.

• Water treatment system.

Employee Development

• Welfare

• Enhance moral

• Skill development

• Performance development

• Performance evaluation

Annual Events

Wesak Dansela

Cricket Match

Health Campaign

Fire Extinguisher Training

Sinhala New Year Function

Annual Trip

Wesak Lantern

Staff Development

Training Program with external Consultant

Training Program with internal Consultant

Best Employee of the Month/Year

Gift for family members

Out door training Program

Point to training courses

Performance evaluation

Foreign tours for employees

Chance to talented persons

Green Productivity

Labour Policies

CSR

• Hospital Repairing

• Ear equipment donate to disable person

• Donation to Buddhist Perahera

• Annual alms giving to Children Home

• Donation for build a temple

• Donation for build a Pagoda

• IT equipment donated to “Kaizen Team”

• Decorated Vehicle to Temple Perahera

ACHIEVEMENTS

Future Plans

• ISO 9001 & ISO 14001

• ERP Solutions

• Monthly tonnage 500 tons

• Better life for employees

• Achieve the VISION

VisionTO BECOME NOUMBER ONE LEADING COMPANY IN PACKAGINGINDUSTRY BY 2020.

© 1996 - Established as a small company without any machine

© 2002 - Incorporated as a Private Limited Company.

© 2004 - Bought 1st lorry for the company.

© 2004 - Company relocated to a new location

© 2010 - Allocated a new building for the business

© 2010 - Joined hands with “Kaizen Entrepreneur” of

National Productivity Secretariat

(Improved physical quality, systems &

productivity methods of our company.)

© 2012 - Bought SORSZ High Quality Offset Printer (Highdelberg)

© 2012 - Bought a new land for Large Expansion

© 2013 - Bought a shoe factory & formed as

"Cavallo Leather Products (Pvt) Ltd.”

© 2013 - Started construction of a New Building

© 2013 - Bought high quality, fully automated brand new machines

History