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Client
ITO EN, United States of America
Project Outline
- “AS IS” Process study & Mapping for a
- Coffee Manufacturing & Distribution
- Herbal and Vitamin Manufacturing & Distribution
- Juice Manufacturing & Distribution
Functional Areas Covered
- Demand Forecasting
- Production Planning – including Automatic Trigger from Inventory Management
- Purchase Management – including Automatic Trigger from Inventory Management
- Warehouse Management – including Automatic Put Away, Picking, Replenishments
- Sales Order Management
- Delivery Management
- Quality Management
Benefits to Customer
ü Smooth Work Flow – No reminders / Follow up
Paper “Less” to Paperless Office.
Client
- Reliance Retail (Chennai, Madurai & Coimbatore DCs) – SAP WMS
- Saint Gobain Glass (Chennai Plant – Mother WH, Delhi – Feeder WH) – SAP SD & Logistics of Glass (LG)
Project Outline
- Warehouse Capacity Workings – Receiving, Put Away, Storage, Picking & Delivery
- Warehouse Layout & Facilities Planning
- Area Calculations
- No of Racks / Bins Required – Mezzanine & Non Mezzanine
- Facilities & Utilities Planning
- MHE requirements
- Manpower Planning
Warehouse Management Systems (WMS) – Design, Implementation & Training
- Receipt, Put Away, Inventory Management, Picking, Staging and Delivery
- The TO BE Process includes Automatic Put Away, Picking & Replenishment strategies.
Benefits to Customer
- Error Proof Layout – Single Flow concept, No scope for mixing – leading to High Inventory Accuracy Levels
- High Productivity levels – Avg 900 lines per Picker achieved. Highest across 23 DCs in India.
Client
- Saravana Stores, Chennai – SAP Business One
Before
- 3 Hyper Stores operating in Chennai.
- Mostly manual Process except payment Processing to Vendors.
- High level of Stock inaccuracies. For instance
- Few lakhs of Stock Write Off only for Kareel Leaves over 6 months.
Duration : 1 Month
After
- Process Blue Print developed for SAP WMS (Wet) operations
- Complete integration of Data between SAP – WMS to Billing System leading to Zero Inventory loss.
- Same Manpower for 5 Hyper Operations – No Increase in Manpower. Job Enhancement projected.
Benefits to Customer
Error Proof Operations – Frequent Write Offs eliminated.
- Highly Visible Inventory at every stage – Sales Counters, Back End Stores, In Receipt etc.
- Faster Replenishment to Sales Counters – less Opportunity loss.
Client
- Autoprint, Coimbatore – Inhouse Developed s/w
- OPG PowerGen Pvt Ltd, Chennai – SAP R3
Before
Autoprint, CBE | OPG Power Gen, Chennai |
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What was done
- ABC – XYZ analysis done on Components / Parts / Consumables.
- Criticality to Machine Building arrived. Highly Critical, Can be managed, Not Critical
- Inventory Norms (Min / Max Stock, ROL, ROQ) arrived at based on lead times of Procurement.
Benefits to Customer
Autoprint, CBE | OPG Power Gen, Chennai |
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Client
- Giri Trading Company, Chennai – SAP Business One
Before
- 22 Stores in Tamil Nadu, Karnataka, Delhi & Maharashtra.
- Central Warehouse in Chennai.
- High level of Stock inaccuracies.
- Delayed Services to Stores.
Inventory maintained is slightly more than actual Sales Turn Over. (Inventory evaluated @ Sales price) leading to Cash crunch.
After
- Process Blue Print developed for SAP WMS (Retail) operations
- ABC Analysis done and Re-Order Level (RoL) fixing for Top Moving Items.
- “Flow Thru Concept” – for Slow Moving items. No Storage in Warehouse.
- Warehouse Space Management Improved and Inventory levels brought down improving Cash flow.
Benefits to Customer
- Error Proof Operations – Warehouse Stock Accuracy Improved leading to faster Deliveries.
- Cash Flow Improved
Client
- Autoprint, Coimbatore
- OPG PowerGen, Chennai
- Chettinadu Cements, Chennai
Before
- No Clear Job Descriptions for each Role level of Stock inaccuracies.
- No Objective Goal Setting & Measurement
- Salary Increments – NOT linked to Performance
After
- Goals Developed based on Balance Score Card for each role.
- Job Descriptions, KRA, KPI defined for each role.
- Performance based Goal Evaluation and Appraisals
- HR – Systems & SOPs Manual
Benefits to Customer
- Personal Bias Removed in appraisals.
- Better Role Clarity