A chemical plant can make a good batch and still lose the paperwork that proves it.

1. 01Production

   Yield drifts and nobody sees it until the month end

   What it looks like

   A batch that used to give 94 kg per 100 kg of input now gives 90. It happens over three weeks, across two shifts, with a new operator on one and a worn agitator on the other. The monthly report shows it after the material is already gone.

   What it costs you

   Example arithmetic: a product with ₹120 per kg of input and 4 percent yield loss on 40 tonnes a month loses about ₹1.9 lakh a month.

   How Verity fixes it

   Each batch records inputs and output against the standard recipe. Verity shows yield by product, shift and reactor, flags a batch that falls outside your range on the day it closes, and lists the batches behind the drift.

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2. 02Traceability

   Nobody can say which raw material lot went into which batch

   What it looks like

   Three suppliers send the same solvent. Drums are issued from stores by whichever is nearest. A customer reports a colour issue and the plant cannot say whether it came from the March lot or the April one.

   What it costs you

   Without lot-to-batch links, one complaint can mean holding every batch made in that period. The real cost is the stock you stop selling while you search.

   How Verity fixes it

   Raw material lots are received with supplier, date and test result. Each batch records which lots were issued to it. Verity shows, both ways, every batch a lot went into and every lot a batch used.

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3. 03Quality

   Certificates of analysis are late, retyped or wrong

   What it looks like

   The lab result is on a sheet. The dispatch clerk retypes it into a certificate at the last minute while the truck waits. A decimal goes wrong, or a result from the previous batch is reused.

   What it costs you

   A wrong certificate is a returned consignment, a credit note and a customer who now double checks everything you send.

   How Verity fixes it

   Lab results are recorded against the batch and drawn into the certificate from that record, not retyped. Dispatch is held until the batch is released by the person who has the right to release it.

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4. 04Quality

   A complaint arrives and the retained sample is nowhere

   What it looks like

   A buyer says the last drum failed their incoming test. The retained sample for that batch should be on a shelf, but the shelf has no labels. The batch sheet is in a box from last year.

   What it costs you

   A complaint you cannot investigate is one you have to accept. It also costs the regular order that follows.

   How Verity fixes it

   Each complaint is a record linked to the batch, the customer, the dispatch and the retained sample location. The investigation, the finding and any credit are recorded on it, and the open ones are listed by age.

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5. 05Safety

   The safety data sheet is out of date, or did not go with the truck

   What it looks like

   The product formulation changed in July. The safety data sheet on file is from last year. A new customer asks for the current one and a driver arrives at a plant without it.

   What it costs you

   The Manufacture, Storage and Import of Hazardous Chemicals Rules treat safety data sheets as part of hazard communication. A missing or stale sheet is a compliance gap and a customer trust problem.

   How Verity fixes it

   Each product holds its current safety data sheet as a record with a version and review date. Verity lists sheets due for review, and a dispatch cannot be closed until the current sheet is recorded as sent with it.

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6. 06Dispatch

   Hazardous goods dispatch papers are done in a hurry

   What it looks like

   The tanker is loaded, the label is on, but the transport emergency card, the driver's trained status and the vehicle papers are checked by whoever remembers. A dispatch goes out with one missing.

   What it costs you

   A stopped vehicle on the road, a delayed delivery and in the worst case an unprepared response to a leak.

   How Verity fixes it

   A dispatch checklist per product class: label, emergency card, driver and vehicle details, quantity against order. The gate supervisor signs it off, and Verity records who and when against the dispatch.

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7. 07Stores

   Drums of different products share the same godown

   What it looks like

   Stock has grown in the past quarter. Oxidisers sit near solvents because that is where space was. Nobody has written down which products are held where, or the limit for each area.

   What it costs you

   A storage mistake is a safety risk first and a licence problem next. It also means stock is hard to find when an order comes in.

   How Verity fixes it

   Each storage location is a record with the products allowed and quantity limits you set. Verity shows what is stored where, warns when a receipt would break your own limit, and lists the oldest stock per location.

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8. 08Compliance

   Effluent and hazardous waste records are filled in before the audit

   What it looks like

   Effluent readings, waste generated, waste sent out and manifests live on different sheets. The annual return is due and the person who knows the numbers is on leave.

   What it costs you

   Waste rules in India require records and an annual return to the State Pollution Control Board, and a gap can lead to notices or consent trouble.

   How Verity fixes it

   Daily effluent readings, waste generated and each manifest are recorded as they happen. Verity totals them by month and year so the annual return figures are already on screen, and flags a missing entry the same day.

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9. 09Compliance

   Consent, authorisation and licence dates sit with one person

   What it looks like

   The consent to operate, hazardous waste authorisation, factory licence, boiler certificate and fire clearance each expire on a different date. The consultant knows them. If the consultant changes, nobody does.

   What it costs you

   A lapsed consent can stop production. The cost is the days of lost output and the fee to regularise.

   How Verity fixes it

   Each licence, consent and certificate is a record with number, authority, expiry and owner. Renewal tasks open weeks ahead and carry the documents needed.

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10. 10Equipment

    The reactor stops because a gasket was never replaced

    What it looks like

    A reactor seal leaks during a batch. The spare was not in stores. The vendor is two days away. Planned maintenance is on a whiteboard that was wiped last month.

    What it costs you

    A stopped batch loses material in process and the delivery date with it. Unplanned stops cost more than planned ones.

    How Verity fixes it

    Each reactor, pump, boiler and pressure vessel is an asset record with service history, spares and next due date. Maintenance becomes a scheduled task with a person, and Verity flags overdue ones.

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11. 11Costing

    Raw material prices move and the quote does not

    What it looks like

    A solvent rate goes up 8 percent. Sales quotes are still on last quarter's price list. The cost of a batch includes losses, recovered solvent and fuel that nobody has worked out.

    What it costs you

    Example arithmetic: a ₹95 per kg product with ₹70 of material, ₹12 of conversion and a 6 percent hidden loss earns about ₹9 per kg, not the ₹13 the price list suggests.

    How Verity fixes it

    Every purchase records the rate. Verity costs each batch from actual lot rates, yield and conversion, and shows the margin per product and per customer, so a price rise shows up as a changed margin the same week.

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12. 12Money

    Customers pay late and the plant finds out when cash is short

    What it looks like

    Four customers owe more than 90 days. The accounts person chases when asked. Meanwhile the plant buys raw material on shorter terms.

    What it costs you

    Example arithmetic: ₹60 lakh outstanding beyond 60 days, financed at 12 percent, costs about ₹60,000 a month in interest alone. Where you are the seller to a small buyer, the MSME payment rules also matter to them.

    How Verity fixes it

    Each invoice is tracked against the dispatch, due date and customer's usual pay days. Verity lists overdue amounts by customer and age, and creates a follow-up task for the person who owns the relationship. Staff make the call.

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13. 13Orders

    Sales promises a date the plant cannot meet

    What it looks like

    A customer asks for 8 tonnes by Friday. Sales says yes. The plant has one reactor booked for another product until Thursday and the raw material has not arrived.

    What it costs you

    A missed date is a lost customer. Over-promising also forces expensive air freight or overtime to catch up.

    How Verity fixes it

    Orders show required quantity, raw material available, reactor slots and expected finish. The planner sees conflicts before a date is confirmed.

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14. 14People

    Operator training, PPE and permits are not recorded

    What it looks like

    A new operator is moved to a hazardous step on his second week. Nobody remembers if his induction and PPE issue were completed. A hot work permit is a paper slip.

    What it costs you

    A person without the right training in a chemical process is a safety risk and, after an incident, a record you cannot produce.

    How Verity fixes it

    Each person's training, induction, PPE issue and station clearance are records with dates. Permits for hot work and entry are tasks with sign-off, and shifts are set from who is cleared.

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15. 15Owner

    The owner reads the plant through phone calls

    What it looks like

    The owner asks what was made today, what is pending dispatch and who has not paid. Each answer is a different person on a different call. By evening the picture is already old.

    What it costs you

    Decisions run on memory and calls. Small gaps in yield, stock and dues compound before they are seen.

    How Verity fixes it

    One morning screen with production, yield flags, stock below reorder, compliance dates due, dispatches and overdue dues, each item with an owner.

    See the screen

Illustrative screens with sample data. Layouts, fields, names and terms are set up around how your chemical plant works.

1. Week 1

   Discovery and mapping

   What we do

   Spend a shift in your plant. Follow a lot from receipt to a finished batch to a loaded truck, and note where records are made and where they are lost.

   What we need from you

   Two to three hours of yours and your plant head's. Access to a few batch sheets, a month of dispatches and the compliance calendar.

   What you have at the end

   A written map of your plant: products, recipes, lots, storage areas, licences, and the first gaps we will close.

2. Weeks 2 to 3

   Configuration

   What we do

   Set up products and recipes, yield ranges, lot and batch numbering, storage limits, dispatch checklists, licence and consent dates, equipment and the five screens, in your own terms.

   What we need from you

   Check the setup with the lab head and the stores in charge. Tell us where a range or a rule is wrong.

   What you have at the end

   A working Verity with your real products, rules and people, ready for your data.

3. Weeks 3 to 4

   Migration and training

   What we do

   Bring in your customers, products, stock, licence dates and open dues from your sheets and accounts export. Train stores, the lab, the gate and the accounts desk at their own stations.

   What we need from you

   An opening stock count by lot, the open dues list and the licence copies. One hour with each role.

   What you have at the end

   Your plant's data inside Verity and a team that has used it through a real batch and dispatch.

4. After go-live

   Operations partnership

   What we do

   Stay on after launch. Review the first weeks of yields and dues with you, tune limits, and change setup when you add a product, a reactor or a storage area.

   What we need from you

   A short monthly review of what the numbers say.

   What you have at the end

   A system that keeps matching how the plant runs, with someone responsible for it.

• Owner

  Is the plant making money, and what is at risk?

  Yield, margin per product, overdue dues, licence dates and every unit side by side.

• Plant head

  What ran, what stopped and what is due?

  Batches closed, yield flags, equipment tasks, permits and compliance dates.

• Lab head

  What is released, held or under investigation?

  Batch results, retained samples, complaints and certificate status.

• Stores and dispatch

  What came in, what is going out and is it cleared?

  Lots received, storage limits, dispatch checklists and the current safety sheet.

• Accounts

  What was bought, sold and owed?

  Invoices tied to dispatches, overdue dues by customer and supplier bills with due dates.