Warehouse Transformation for an Indian steel and energy company

Warehouse Transformation Solution design for an Indian steel and energy company. This would be a ‘Transformation Change’ across all existing Warehouses as well as the Upcoming Warehouses of the Textiles sector of that company. The Supply chain in discussion is from the Yarn storage, Processing, Roll Storage and Transportation to Customers.

Warehouse Transformation Solution Design:

1. Location Management System: The products would be tracked at a Location Level and we move away from the current practice of Zone level tracking.
2. Inventory Management System: Process Implementation and Training of Inventory Management in-terms of Traceability, Retrievability, Accuracy and Preservation.
3. Re-arrangement Algorithms Implementation: In-House system for company to tag high performers & Ensuring Fast Movers at Golden Zones ensuring Improvement in Productivity.
4. Warehouse Management: Process Standardization across the warehouse of the company through warehouse process documentation, standardization, deployment at POU and training.
5. Management Information System: Set up all leading and lagging process Indicators in Warehouse to ensure the business objectives and customer service levels are met.
6. 5S Implementation | Through 5S Implementation the Warehouse would be taken to Global Standards improving all Major metrics of Warehouse.

Value Proposition:

• Productivity Improvement | Streamlined end to end of Process resulting in Better Productivity (Minimum 25-30%)
• Space Optimization | Stock management (fast movers in fast pick zones and dead stock bulk storage) could result in at-least space savings of around 20-30%
• Service Levels | Efficient Process Implementation will improve the Pick Accuracy and avoid Mis-Shipment to Customers.

YARN Warehouse

1. Space Planning | The Product forecast and the SKU parameters have to be modelled to estimate the space forecast for the Warehouse.
2. Rack Design: Set up all leading and lagging process Indicators in Warehouse to ensure the business objectives and customer service levels are met.
3. Material Handling: Through 5S Implementation the Warehouse would be taken to Global Standards improving all Major metrics of Warehouse.
4. Material Flow: Traffic Study and efficient material flow route will be implemented.
5. Barcode Implementation: Throughout the Warehouse Through put Barcode will be implemented. Location management system will also be implemented.
6. WMS Implementation
7. FIFO Implementation for Yarn Warehouse

Value Proposition:

• Space Optimization | 3X Space Utilization from current Levels.
• Productivity | Streamlined end to end of Process resulting in Better Productivity (Minimum 25-30%).
• Service Levels | Efficient Process Implementation will improve the Pick Accuracy and avoid Mis-Shipment to Customers.