WAREHOUSING ACTIVITIES FLOW CHART

RECEIVE GOODS

IDENTIFY GOODS (SKU)

DISPATCH TO STORAGE

HOLD GOODS

PICK GOODS

MARSHAL SHIPMENT

DISPATCH SHIPMENT

UPDATE INFORMATIONS SYSTEM

PROJECT FLOW CHART

OBJECTIVE OF THE PROJECT

IDENTIFY NEEDS
&
REQUIREMENTS

DESIGN SKUS POSITION

AS PER THE REQUIREMENTS

COMMISSION THE WAREHOUSE

DEFINE KPIS

TRACK & MEASURE KPIS

PERIODIC REVIEW
OBJECTIVE:

To study of the warehouse racking and automation systems and propose a system for the newly
commissioned FG Warehouse

IDENTIFY NEEDS AND REQUIREMENTS:

Requirements
o Goods to be stored
HDPE
PM -
FG Inventory 40% of 3P Units production i.e., 18000 Cartons

FG SKUS HDPE GRADES/SKUS PM SKUS

30 FT HDPE BM GRADE B56003 RELIANCE CAP PCNO 200/500 ML UTTAM FT
30 FT NIHAR UTTAM HDPE BM GRADE - F46003 RELIANCE PLUG PCNO 1/2 LTR POLY JAR
48 FT HDPE BM GRADE B6401 HALDIA CAP PCNO 50/100 ML FT UTTAM
50 FT HDPE BM GRADE - E 5201S HALDIA CAP PCNO 50/100 ML FT HINDI (NEW)
40 FT HDPE BM GRADE B60003 RELIANCE CAP PCNO 200/500 ML FT HINDI (NEW)
50 FT NIHAR UTTAM HDPE BM GRADE B6401 IOCAL CAP PCNO 1/2 LTR POLY JAR-NEW
100ML FT-192(N) NEW MRP CAP PCNO 200 ML EASY JAR HINDI-NEW
100 FT PRICE OFFER CAP PCNO 500 ML EASY JAR HINDI-NEW
120 FT NIHAR UTTAM
175 FT
175 FT NIHAR UTTAM
175 + 25 FT PCNO
200 FT PCNO CSD
250 FT OLD MRP
250 FT New MRP
175 FT + 25 FT UTTAM
250 FT OFFER
300 FT
500 FT
600 FT
175 EJ + 25 EJ
175 EJ
200 EJ CSD
250 EJ
300 EJ
1 L PJ
2 LTR PJ
 o Daily inflow of FG from all the 3P plants
Plant Wise Average
o Daily outflow of Raw material for all 3P Plants
HDPE
PM
Needs
o HDPE : Need to stock requirement of 6 months
o PM: Need to stock requirement of 3 months

WAREHOUSE SPECIFICATIONS

Available Space: 24000 SFT

No of Floors : 2
Need to Accommodate
o Office Room
o Storage space

KEY PERFORMANCE INDICATORS

Define KPIs
o Supply Chain
Transport Efficiency
Deviation in same day dispatch
Truck Detention
Truck Delayed received more than 3 days
Unloading time
Loading time
o Commercial
Stock Variance
Sales Returns count
Loose oil Salvage efficiency
o Quality & Safety
Quality Complaints count
Theft Control
CC Camera
Labor safety systems
o Human Efficiency
Daily Labor Efficiency
METHODOLOGY OF STACKING

Start filling Light weight goods on the first floor i.e.,

o PM Inventory
o HDPE
Heavy weight goods on the ground floor
o FG storage close to marshaling area
Loading and Unloading to be at separate areas
o Preferably on opposite ends of the warehouse
Follow FIFO

TRACEABILITY

FG
o Individual slot assignment for individual SKU, plant wise
o Within SKU, color codes to be applied
FG Based on manufacturing dates
Within 1 Week Red
More than 1 week to Less than one month Yellow
More than one month Green
Dispatch flow
Green Color coded items will move First
Yellow color coded will follow
Red ones are not be dispatched
HDPE/PM
o One side of First floor for HDPE & PM separately
HDPE
These have to be sorted and arranged as per the grades.
RM
These have to be sorted and arranged as per their predefined sizes for quicker
identification.

CONSTRAINTS

Labor issues
Logistics issues - Lorry Strikes
Demand Variability
Tracking multiple SKUs each plant wise for FG is a challenge.
FG Inventory Warehouse Design

To Villupuram to Pondi

B1 B22

To
B2 B21
Palayam Road

B3 B20

B4 B19

B5
B18

B6 B17
Vehicle
Entry/Exit
B7 B16
Unloading/L
oading
Point
B8 B15

CCTV
Camera B9 B14

B10 B13

B11 B12
Individual Bay Break up

Fast Moving Medium Moving Slow Moving

SKUs
FG Warehouse Slot Allotment

3P UNIT NAME EXPECTED CARTONS SKUs to be Allotted SLOT ASSIGNED

@40%
SHIVAM 5211 6 B19 to B22
AMEYA PLASTICS 2657 3 B16 to B18
SOWPARNIKA 740 4 B1 to B2
Sree Mookambai 3106 2 B3 to B5
ANUGHA.2 1622 4 B6 to B8
PREMIER 872 4 B8 to B9
SRINIVASA PACK 536 1 B10
MORESWAR.2 0 0 B11
Emox 3336 4 B13 to B15

Points to Remember

Main/Side Gates will be alternatively used for entry/exit into the parking area.
5 Entry/exit points of the warehouse available at the main entrance side will be used for
Unloading/Loading.
o Loading i.e., Dispatch will always take priority.
o For all local unloading, we can use the other 3 entry/exit points, when dispatch is underway.
There should not be a single carton, which is not palletized.
Any movement unloading/loading/within warehouse should only happen through pallets.
First Floor Design (HDPE/PM)

B1 B22

B2 B21

B3 B20

B4 B19

B5
B18

B6 B17

B7 B16

B8 B15

B9 B14

B10 B13

B11 B12

Points to Remember

HDPE will occupy all the bays from B12 to B22

PM will occupy all the bays from B11 to B1
As first floor, has 2 entry/exit points, we can use one for loading and other for unloading, so that we
have a structured flow of materials.
DAILY CHECKS

Walk through Audit for the following

o Leakages/Spillages of oil
o Stock Variance
o Warehousing Cleaning

SAFETY MEASURES

Common Mishaps at Loading Docks and Storage Areas

o Product falling onto employees head, feet, arms, and legs
o Weak housekeeping programs that result in congestion
o Employees jumping from a high elevation to a lower elevation
o Forklift or pallet jacks rolling off the dock

Controls Include
o Conducting daily inspections of loads and temporary storage arrangements.
o Never allowing a forklift or pallet jack to back to the edge of the dock
o Enforcing safety rules about employee movement from higher dock elevations to the lower ground
surface.
o Monitoring assigned safety inspection forms

SECURITY PERSONNEL ROLES

Gate Control
o Main Gate Control
o Side 2nd Gate Control
Inward Maintenance
o HDPE/PM
o FG
Outward Maintenance
o HDPE/PM
o FG
Warehouse Maintenance
o Sealing of all Shutters
o Fire extinguisher Maintenance
o Estate truck traffic
o 2 Floors Multiple operations
o Daily Visitor Register Maintenance
o Allocation of Space
o Stock Storage Norms and Maintenance
Truck Sealing
o FG Trucks
o HDPE/PM Trucks
 Loading/unloading Details count
Stock Identification & Traceability

EXPECTED OUTCOME

Efficient and cost effective racking and storage systems.

Reduced time in terms of Loading and Unloading materials

FUTURE SCOPE

Operating 3P units might come down to 3 from 9. This has direct impact on warehousing operations.
SKUs and current production values may differ owing to market conditions.