Lines

Stage-by-stage synchronization and the constraint between stages.

Flow Matrix Timeline

Log shift update

Facility:All Facilities Palghar Unit I Palghar Unit II Palghar Unit III Palghar Tablet Unit Greenfield Plant

Shift B in progress (6.7%)

Primary bottleneck · Stage 3 to 4

Stage 3 to 4: 420 kg queued. downstream capacity does not exceed inflow. Manual intervention needed.

Queued: 420kg
Oldest lot: 9.5h
Breach in: 0.0h

Why?

Why this is the constraint

Changeover excess: −11.5 kg · 33.9%
Unplanned downtime: −14.8 kg · 43.6%
Crew shortfall: −7.7 kg · 22.5%

Palghar Unit I

Continuous Synchronized Stage Flow · 7 Sequential Processing Work-Centers

35 Total Lines

STAGE 15 lines

Dispensing & Kitting

Capsule Filler Line 1

Capsule Filler Line 1 - Intake Unit

Running 32m

Bharat Nutra·capsule-solid

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Blister Line 1

Blister Line 1 - Intake Unit

Running 32m

Citrus Wellness·tablet-coated

vs Plan70%/ 100%

vs Rated66.5%/ 85%

Sachet Line 1

Sachet Line 1 - Intake Unit

Running 32m

Dhanvantari Labs·nutra-sachet

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Blister Line 2

Blister Line 2 - Intake Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.04%/ 100%

vs Rated89.33%/ 85%

Cartoning Line 1

Cartoning Line 1 - Intake Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.08%/ 100%

vs Rated89.38%/ 85%

65 kg·3 drums·2.5 h

16415.3 kg/h· 16415.3 kg/hcannot clear

STAGE 25 lines

Granulation / Mixing

Capsule Filler Line 1

Capsule Filler Line 1 - Dispensing Unit

Running 32m

Bharat Nutra·capsule-solid

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Blister Line 1

Blister Line 1 - Dispensing Unit

Running 32m

Citrus Wellness·tablet-coated

vs Plan70%/ 100%

vs Rated66.5%/ 85%

Sachet Line 1

Sachet Line 1 - Dispensing Unit

Running 32m

Dhanvantari Labs·nutra-sachet

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Blister Line 2

Blister Line 2 - Dispensing Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.04%/ 100%

vs Rated89.33%/ 85%

Cartoning Line 1

Cartoning Line 1 - Dispensing Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.08%/ 100%

vs Rated89.38%/ 85%

80 kg·4 drums·2.5 h

16415.3 kg/h· 16415.3 kg/hcannot clear

STAGE 35 lines

Compression / Blending

Capsule Filler Line 1

Capsule Filler Line 1 - Bulk Unit

Running 32m

Bharat Nutra·capsule-solid

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Blister Line 1

Blister Line 1 - Bulk Unit

Running 32m

Citrus Wellness·tablet-coated

vs Plan70%/ 100%

vs Rated66.5%/ 85%

Sachet Line 1

Sachet Line 1 - Bulk Unit

Running 32m

Dhanvantari Labs·nutra-sachet

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Blister Line 2

Blister Line 2 - Bulk Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.04%/ 100%

vs Rated89.33%/ 85%

Cartoning Line 1

Cartoning Line 1 - Bulk Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.08%/ 100%

vs Rated89.38%/ 85%

Hero Bottleneck

420 kg·14 drums·9.5 h

140.3 kg/h· 49.9 kg/hcannot clear

STAGE 45 lines

Primary Packaging / Blister

Capsule Filler Line 1

Capsule Filler Line 1 - Primary Packaging Unit

Running 32m

Bharat Nutra·capsule-solid

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Blister Line 1

Blister Line 1 - Primary Packaging Unit

Running 32m

Citrus Wellness·tablet-coated

vs Plan70%/ 100%

vs Rated66.5%/ 85%

Sachet Line 1

Sachet Line 1 - Primary Packaging Unit

Running 32m

Dhanvantari Labs·nutra-sachet

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Blister Line 2

Blister Line 2 - Primary Packaging Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.04%/ 100%

vs Rated89.33%/ 85%

Cartoning Line 1

Cartoning Line 1 - Primary Packaging Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.08%/ 100%

vs Rated89.38%/ 85%

110 kg·5 drums·2.5 h

16415.3 kg/h· 16415.3 kg/hcannot clear

STAGE 55 lines

Secondary Packaging

Capsule Filler Line 1

Capsule Filler Line 1 - Secondary Packaging Unit

Running 32m

Bharat Nutra·capsule-solid

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Blister Line 1

Blister Line 1 - Secondary Packaging Unit

Running 32m

Citrus Wellness·tablet-coated

vs Plan70%/ 100%

vs Rated66.5%/ 85%

Sachet Line 1

Sachet Line 1 - Secondary Packaging Unit

Running 32m

Dhanvantari Labs·nutra-sachet

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Blister Line 2

Blister Line 2 - Secondary Packaging Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.04%/ 100%

vs Rated89.33%/ 85%

Cartoning Line 1

Cartoning Line 1 - Secondary Packaging Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.08%/ 100%

vs Rated89.38%/ 85%

125 kg·5 drums·2.5 h

16415.3 kg/h· 16415.3 kg/hcannot clear

STAGE 65 lines

QC and Release

Capsule Filler Line 1

Capsule Filler Line 1 - QC and Release Unit

Running 32m

Bharat Nutra·capsule-solid

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Blister Line 1

Blister Line 1 - QC and Release Unit

Running 32m

Citrus Wellness·tablet-coated

vs Plan70%/ 100%

vs Rated66.5%/ 85%

Sachet Line 1

Sachet Line 1 - QC and Release Unit

Running 32m

Dhanvantari Labs·nutra-sachet

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Blister Line 2

Blister Line 2 - QC and Release Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.04%/ 100%

vs Rated89.33%/ 85%

Cartoning Line 1

Cartoning Line 1 - QC and Release Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.08%/ 100%

vs Rated89.38%/ 85%

140 kg·6 drums·2.5 h

16415.3 kg/h· 16415.3 kg/hcannot clear

STAGE 75 lines

Dispatch

Capsule Filler Line 1

Capsule Filler Line 1 - Dispatch Unit

Running 32m

Bharat Nutra·capsule-solid

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Blister Line 1

Blister Line 1 - Dispatch Unit

Running 32m

Citrus Wellness·tablet-coated

vs Plan70%/ 100%

vs Rated66.5%/ 85%

Sachet Line 1

Sachet Line 1 - Dispatch Unit

Running 32m

Dhanvantari Labs·nutra-sachet

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Blister Line 2

Blister Line 2 - Dispatch Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.04%/ 100%

vs Rated89.33%/ 85%

Cartoning Line 1

Cartoning Line 1 - Dispatch Unit

Running 32m

Contract Account 270·capsule-solid

vs Plan94.08%/ 100%

vs Rated89.38%/ 85%

Palghar Unit II

Continuous Synchronized Stage Flow · 7 Sequential Processing Work-Centers

14 Total Lines

STAGE 12 lines

Dispensing & Kitting

Cosmetic Tube Line

Cosmetic Tube Line - Intake Unit

Running 32m

EverHealth Sciences·topical-cream

vs Plan92%/ 100%

vs Rated87.4%/ 85%

Aerosol Line 1

Aerosol Line 1 - Intake Unit

Running 32m

Fiona Cosmetics·oral-liquid

vs Plan93%/ 100%

vs Rated88.35%/ 85%

65 kg·3 drums·2.5 h

2002.1 kg/h· 2002.1 kg/hcannot clear

STAGE 22 lines

Granulation / Mixing

Cosmetic Tube Line

Cosmetic Tube Line - Dispensing Unit

Running 32m

EverHealth Sciences·topical-cream

vs Plan92%/ 100%

vs Rated87.4%/ 85%

Aerosol Line 1

Aerosol Line 1 - Dispensing Unit

Running 32m

Fiona Cosmetics·oral-liquid

vs Plan93%/ 100%

vs Rated88.35%/ 85%

80 kg·4 drums·2.5 h

2002.1 kg/h· 2002.1 kg/hcannot clear

STAGE 32 lines

Compression / Blending

Cosmetic Tube Line

Cosmetic Tube Line - Bulk Unit

Running 32m

EverHealth Sciences·topical-cream

vs Plan92%/ 100%

vs Rated87.4%/ 85%

Aerosol Line 1

Aerosol Line 1 - Bulk Unit

Running 32m

Fiona Cosmetics·oral-liquid

vs Plan93%/ 100%

vs Rated88.35%/ 85%

95 kg·4 drums·2.5 h

2002.1 kg/h· 2002.1 kg/hcannot clear

STAGE 42 lines

Primary Packaging / Blister

Cosmetic Tube Line

Cosmetic Tube Line - Primary Packaging Unit

Running 32m

EverHealth Sciences·topical-cream

vs Plan92%/ 100%

vs Rated87.4%/ 85%

Aerosol Line 1

Aerosol Line 1 - Primary Packaging Unit

Running 32m

Fiona Cosmetics·oral-liquid

vs Plan93%/ 100%

vs Rated88.35%/ 85%

110 kg·5 drums·2.5 h

2002.1 kg/h· 2002.1 kg/hcannot clear

STAGE 52 lines

Secondary Packaging

Cosmetic Tube Line

Cosmetic Tube Line - Secondary Packaging Unit

Running 32m

EverHealth Sciences·topical-cream

vs Plan92%/ 100%

vs Rated87.4%/ 85%

Aerosol Line 1

Aerosol Line 1 - Secondary Packaging Unit

Running 32m

Fiona Cosmetics·oral-liquid

vs Plan93%/ 100%

vs Rated88.35%/ 85%

125 kg·5 drums·2.5 h

2002.1 kg/h· 2002.1 kg/hcannot clear

STAGE 62 lines

QC and Release

Cosmetic Tube Line

Cosmetic Tube Line - QC and Release Unit

Running 32m

EverHealth Sciences·topical-cream

vs Plan92%/ 100%

vs Rated87.4%/ 85%

Aerosol Line 1

Aerosol Line 1 - QC and Release Unit

Running 32m

Fiona Cosmetics·oral-liquid

vs Plan93%/ 100%

vs Rated88.35%/ 85%

Hero Bottleneck

140 kg·6 drums·2.5 h

1686.3 kg/h· 1686.3 kg/hcannot clear

STAGE 72 lines

Dispatch

Cosmetic Tube Line

Cosmetic Tube Line - Dispatch Unit

Running 32m

EverHealth Sciences·topical-cream

vs Plan92%/ 100%

vs Rated87.4%/ 85%

Aerosol Line 1

Aerosol Line 1 - Dispatch Unit

Running 32m

Fiona Cosmetics·oral-liquid

vs Plan93%/ 100%

vs Rated88.35%/ 85%

Palghar Unit III

Continuous Synchronized Stage Flow · 7 Sequential Processing Work-Centers

21 Total Lines

STAGE 13 lines

Dispensing & Kitting

Liquid Oral Line A

Liquid Oral Line A - Intake Unit

Running 32m

Greenleaf Nutrition·pet-extrusion

vs Plan94%/ 100%

vs Rated89.3%/ 85%

Liquid Line B

Liquid Line B - Intake Unit

Running 32m

Himalaya Vet Care·capsule-solid

vs Plan95%/ 100%

vs Rated90.25%/ 85%

Bottling Line 1

Bottling Line 1 - Intake Unit

Running 32m

IndiaFirst FMCG·tablet-coated

vs Plan96%/ 100%

vs Rated91.2%/ 85%

65 kg·3 drums·2.5 h

5453 kg/h· 5453 kg/hcannot clear

STAGE 23 lines

Granulation / Mixing

Liquid Oral Line A

Liquid Oral Line A - Dispensing Unit

Running 32m

Greenleaf Nutrition·pet-extrusion

vs Plan94%/ 100%

vs Rated89.3%/ 85%

Liquid Line B

Liquid Line B - Dispensing Unit

Running 32m

Himalaya Vet Care·capsule-solid

vs Plan95%/ 100%

vs Rated90.25%/ 85%

Bottling Line 1

Bottling Line 1 - Dispensing Unit

Running 32m

IndiaFirst FMCG·tablet-coated

vs Plan96%/ 100%

vs Rated91.2%/ 85%

80 kg·4 drums·2.5 h

5453 kg/h· 5453 kg/hcannot clear

STAGE 33 lines

Compression / Blending

Liquid Oral Line A

Liquid Oral Line A - Bulk Unit

Running 32m

Greenleaf Nutrition·pet-extrusion

vs Plan94%/ 100%

vs Rated89.3%/ 85%

Liquid Line B

Liquid Line B - Bulk Unit

Running 32m

Himalaya Vet Care·capsule-solid

vs Plan95%/ 100%

vs Rated90.25%/ 85%

Bottling Line 1

Bottling Line 1 - Bulk Unit

Running 32m

IndiaFirst FMCG·tablet-coated

vs Plan96%/ 100%

vs Rated91.2%/ 85%

95 kg·4 drums·2.5 h

5453 kg/h· 5453 kg/hcannot clear

STAGE 43 lines

Primary Packaging / Blister

Liquid Oral Line A

Liquid Oral Line A - Primary Packaging Unit

Running 32m

Greenleaf Nutrition·pet-extrusion

vs Plan94%/ 100%

vs Rated89.3%/ 85%

Liquid Line B

Liquid Line B - Primary Packaging Unit

Running 32m

Himalaya Vet Care·capsule-solid

vs Plan95%/ 100%

vs Rated90.25%/ 85%

Bottling Line 1

Bottling Line 1 - Primary Packaging Unit

Running 32m

IndiaFirst FMCG·tablet-coated

vs Plan96%/ 100%

vs Rated91.2%/ 85%

110 kg·5 drums·2.5 h

5453 kg/h· 5453 kg/hcannot clear

STAGE 53 lines

Secondary Packaging

Liquid Oral Line A

Liquid Oral Line A - Secondary Packaging Unit

Running 32m

Greenleaf Nutrition·pet-extrusion

vs Plan94%/ 100%

vs Rated89.3%/ 85%

Liquid Line B

Liquid Line B - Secondary Packaging Unit

Running 32m

Himalaya Vet Care·capsule-solid

vs Plan95%/ 100%

vs Rated90.25%/ 85%

Bottling Line 1

Bottling Line 1 - Secondary Packaging Unit

Running 32m

IndiaFirst FMCG·tablet-coated

vs Plan96%/ 100%

vs Rated91.2%/ 85%

125 kg·5 drums·2.5 h

5453 kg/h· 5453 kg/hcannot clear

STAGE 63 lines

QC and Release

Liquid Oral Line A

Liquid Oral Line A - QC and Release Unit

Running 32m

Greenleaf Nutrition·pet-extrusion

vs Plan94%/ 100%

vs Rated89.3%/ 85%

Liquid Line B

Liquid Line B - QC and Release Unit

Running 32m

Himalaya Vet Care·capsule-solid

vs Plan95%/ 100%

vs Rated90.25%/ 85%

Bottling Line 1

Bottling Line 1 - QC and Release Unit

Running 32m

IndiaFirst FMCG·tablet-coated

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Hero Bottleneck

140 kg·6 drums·2.5 h

2717 kg/h· 2717 kg/hcannot clear

STAGE 73 lines

Dispatch

Liquid Oral Line A

Liquid Oral Line A - Dispatch Unit

Running 32m

Greenleaf Nutrition·pet-extrusion

vs Plan94%/ 100%

vs Rated89.3%/ 85%

Liquid Line B

Liquid Line B - Dispatch Unit

Running 32m

Himalaya Vet Care·capsule-solid

vs Plan95%/ 100%

vs Rated90.25%/ 85%

Bottling Line 1

Bottling Line 1 - Dispatch Unit

Running 32m

IndiaFirst FMCG·tablet-coated

vs Plan96%/ 100%

vs Rated91.2%/ 85%

Palghar Tablet Unit

Continuous Synchronized Stage Flow · 7 Sequential Processing Work-Centers

14 Total Lines

STAGE 12 lines

Dispensing & Kitting

Tablet Compression Line 1

Tablet Compression Line 1 - Intake Unit

Running 32m

Jeevika Ayurveda·nutra-sachet

vs Plan95.98%/ 100%

vs Rated91.22%/ 85%

Pet-food Extrusion Line

Pet-food Extrusion Line - Intake Unit

Running 32m

Aarav Pharmaceuticals·topical-cream

vs Plan98%/ 100%

vs Rated93.1%/ 85%

65 kg·3 drums·2.5 h

140.3 kg/h· 140.3 kg/hcannot clear

STAGE 22 lines

Granulation / Mixing

Tablet Compression Line 1

Tablet Compression Line 1 - Dispensing Unit

Running 32m

Jeevika Ayurveda·nutra-sachet

vs Plan95.98%/ 100%

vs Rated91.22%/ 85%

Pet-food Extrusion Line

Pet-food Extrusion Line - Dispensing Unit

Running 32m

Aarav Pharmaceuticals·topical-cream

vs Plan98%/ 100%

vs Rated93.1%/ 85%

80 kg·4 drums·2.5 h

140.3 kg/h· 140.3 kg/hcannot clear

STAGE 32 lines

Compression / Blending

Tablet Compression Line 1

Tablet Compression Line 1 - Bulk Unit

Running 32m

Jeevika Ayurveda·nutra-sachet

vs Plan95.98%/ 100%

vs Rated91.22%/ 85%

Pet-food Extrusion Line

Pet-food Extrusion Line - Bulk Unit

Running 32m

Aarav Pharmaceuticals·topical-cream

vs Plan98%/ 100%

vs Rated93.1%/ 85%

95 kg·4 drums·2.5 h

140.3 kg/h· 140.3 kg/hcannot clear

STAGE 42 lines

Primary Packaging / Blister

Tablet Compression Line 1

Tablet Compression Line 1 - Primary Packaging Unit

Running 32m

Jeevika Ayurveda·nutra-sachet

vs Plan95.98%/ 100%

vs Rated91.22%/ 85%

Pet-food Extrusion Line

Pet-food Extrusion Line - Primary Packaging Unit

Running 32m

Aarav Pharmaceuticals·topical-cream

vs Plan98%/ 100%

vs Rated93.1%/ 85%

110 kg·5 drums·2.5 h

140.3 kg/h· 140.3 kg/hcannot clear

STAGE 52 lines

Secondary Packaging

Tablet Compression Line 1

Tablet Compression Line 1 - Secondary Packaging Unit

Running 32m

Jeevika Ayurveda·nutra-sachet

vs Plan95.98%/ 100%

vs Rated91.22%/ 85%

Pet-food Extrusion Line

Pet-food Extrusion Line - Secondary Packaging Unit

Running 32m

Aarav Pharmaceuticals·topical-cream

vs Plan98%/ 100%

vs Rated93.1%/ 85%

125 kg·5 drums·2.5 h

140.3 kg/h· 140.3 kg/hcannot clear

STAGE 62 lines

QC and Release

Tablet Compression Line 1

Tablet Compression Line 1 - QC and Release Unit

Running 32m

Jeevika Ayurveda·nutra-sachet

vs Plan95.98%/ 100%

vs Rated91.22%/ 85%

Pet-food Extrusion Line

Pet-food Extrusion Line - QC and Release Unit

Running 32m

Aarav Pharmaceuticals·topical-cream

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Hero Bottleneck

140 kg·6 drums·2.5 h

112.8 kg/h· 112.8 kg/hcannot clear

STAGE 72 lines

Dispatch

Tablet Compression Line 1

Tablet Compression Line 1 - Dispatch Unit

Running 32m

Jeevika Ayurveda·nutra-sachet

vs Plan95.98%/ 100%

vs Rated91.22%/ 85%

Pet-food Extrusion Line

Pet-food Extrusion Line - Dispatch Unit

Running 32m

Aarav Pharmaceuticals·topical-cream

vs Plan98%/ 100%

vs Rated93.1%/ 85%

Greenfield Plant

Greenfield Development · Zero Active Commercial Operations

Under Construction

Site Commissioning in Progress

Physical cleanroom validation (Grade C / D suites) and HVAC qualification currently active. Commercial equipment integration scheduled for Phase 2 validation.

Civil Infrastructure: 100% Cleanroom Envelope: 92% Line 1 FAT/SAT: In Progress