CURRENT SCENARIO

SUMMARY OF TOY INDUSTRY, CURRENT STATE OF SIGMA TOYS & ANALYSIS OF FINANCES

MARKET SCENARIO IDENTIFICATION OF ISSUES RECOMMENDATIONS IMPLEMENTATION ROAD-MAP

OVERALL MARKET DESCRIPTION

OF TOY INDUSTRY
US$1.2bn 12% 18% 80% 2.5x 1.2x
Value of Toy Forecasted CAGR Purchases of Population will Increase in Affluent consumers
Industry Market in of domestic Toy Toys are made belong to Gen-I Income per in Tier II & III cities
Sources: Invest India, IBEF, Bain India as of 2020 demand Online by 2027 Capita by 2027 by 2025

1 Overview : Sigma Toys 2 Insights : Target Market & Offered Categories 3 Analysis of Financials
Particulars 2020 2019 2018
Headquartered in Mumbai • Toys Manufactured – Sold
Cost of Revenue 82.71% 81.66% 77.81%
15% market share in Indian Toy Market 95,80,889 Direct Material 79.87% 79.15% 74.38%
Direct Labor 2.84% 2.51% 3.44%
Manufactured Gross Profit 17.29% 18.34% 22.19%
• Manufacturing Plant Locations - Noida, • Toys Sold (Revenue/500)
Internal SG&A 2.41% 2.01% 2.50%
Nagpur, Bhubaneshwar, Lucknow, Rajkot – 91,40,000
External SG&A 5.25% 5.03% 5.63%
EBIT 9.63% 11.31% 14.06%
• Wholesale Distribution Stores - Delhi, • For age group 7-9, 9-12, Interest 0.44% 0.25% 1.25%
Chennai, Kolkata, Goa, Mumbai, Jaipur, and 12+ years, the only Tax 20.45% 20.00% 20.00%
Bhopal, Shimla category is Games and Net income 6.56% 8.54% 9.38%
Puzzle Pre-tax Margin 8.53% 10.80% 12.19%

• Channels of Distribution – Retail only • Cost of Raw Materials has increased

Sigma Toys produces
(21,50,905) more
• Employees – 50 in PVC Manufacturing plant, • Labor Cost of the company has decreased but
8 in Toy Manufacturing Plant, 2 manage toys for infants & pre- it has not had much impact on Gross Profit
Distribution Center Facility school than able to sell
(20,10,800) by 6.9% • Net income has decreased due to increase in
• Average Selling Price – INR 500/piece raw material cost
• Focus age group should
be 3-5 years as it caters to • Company has reduced debt, internal expense
• Price of Rejected Toys – INR 50/toy lot of toys category & increased revenue
 KEY ADDRESSABLE ISSUES
PROBLEMS WITH REVENUE PROBLEMS WITH COST

Sigma Toys lost an opportunity to earn an additional revenue of INR 108 Cr Bhubaneshwar has highest packaging cost, highest error rate &
lowest efficiency, still it receives highest yearly PVC shipment
The company was not able to meet the demand for 2020 by 21 lakh units
increasing final cost
Low Capacity Utilization & Idle time for Equipment is not utilized well
• Packaging cost, error rate & taxes of every toy manufacturing plant vary
• Throughput rate of Reactor Throughput Rate for each Equipment
(R1) is the lowest Output (MT Processing Waiting time
Througput • Despite this, all the plants run at similar capacity utilization of 60%. This increase the cost of
Equipment rate (MT PVC
PVC) time in hours in hours
per hour) the final product
• Thus, R1 proves to be a R1 (Bottleneck) 355 4 4 44
bottleneck in the • Transportation cost rising as no Optimum route from Toy manufacturing plant to distribution
C1 248 1 0 248
manufacturing process center has been found
E1 213 0.5 0 426

• PVC production capacity per D1 195 1.5 0 130 • Employee attrition is high, due to hectic working schedule resulting in increased
day is lower than expected M1 177 1 0 177 costs of hiring and training new joiners

• Scrapped Toys are sold at average INR 50, despite cost of toys amounting to • The company is facing shelf availability issues leading to opportunity cost
approximately INR 350 • Sigma Toys has high error rate at some plant locations
• Company only uses Retail Channel for sales, highly limiting their revenue increasing options

Gantt Chart highlighting inefficiencies in the PVC Manufacturing Plant. Click the chart to view the complete Day’s Operations. Legend: In Process Idle Cannot be Used
Equipment/
12-12.30 12.30-1 1-1.30 1.30-2 2-2.30 2.30-3 3-3.30 3.30-4 4-4.30 4.30-5 5-5.30 5.30-6 6-6.30 6.30-7 7-7.30 7.30-8
Time
R1
C1
E1
D1
M1
Cycles Cycle 1
 RECOMMENDATIONS
TO INCREASE THE REVENUE AND REDUCE THE COSTS FOR SIGMA TOYS

1 Installing Additional Reactor 2

Source: GEP Software
Process flow after adding new
reactor at PVC Manufacturing Plant

• The solution will help Sigma Toys manage their increased supply of raw material efficiently

• The seamless integration from sourcing to contracting to order would reduce burden on employees and
improve working conditions for them
• Introduce a new reactor R2, which would help the company utilize the idle time of
other equipment
• This will help the company get real time visibility on cost saving initiatives and help improve bottom line
• Since, Sigma Toys could use maximum of 90% capacity of current reactor (R1), it
• Gig workers can be monitored through contract management such that peak demand season is met with
would not be possible to meet the growing demands of toys as it could generate
adequate supply
maximum of 196 MT PVC per cycle

• 44 MT PVC is required at final stage from R2, by doing the backward calculation, 3 New Scrappage Policy
company would require 90 MT PVC at the output of R2
• Segmenting toys into 4 categories – Bronze, Silver, Gold & Silver, the toys can be sold at varied prices
• This can be achieved by using 20% capacity utilization of R2. Further, capacity according to the segments they belong to
utilization of other equipment's would also change. For T1, A1, B1, T2 and WH1,
• Toys which do not meet the quality standards but
capacity utilization would increase to 63%
still of good quality can be categorized as Platinum
while Toys of very poor quality can be categorized
as Bronze

Platinum Scrappage can be sold online and to

dealers without Sigma Toys Label at 80% of the
MRP, while Bronze can be sold at INR 50