Our client, a third generation entrepreneur, was running his warehouse in-house based on principles which was founded by his predecessors. Operations are 100% Box-In & Piece-Out.

While orders were being fulfilled, however warehouse was jam packed with inventory, locating slow moving items took unnaturally high time to locate leading to delay in delivery of orders, inventory was unloaded based on area available instead of where it is actually supposed to be kept, Manpower productivity was hampered leading to high overtime.

For the company- timely servicing of customer order is of paramount importance, hence entire focus and effort was towards delivering orders on time, leaving warehouse in chaos. Market returned SRN products were not attended for more than 6 to 8 months and Credit Note was also not issued to the parties. With 40 year old reputation at stake, warehouse needed to adapt.

Solution:

Redesigned Inventory Storage systems: Warehouse Storage Plan was completely redesigned based on type and category and movement of inventory. Separate storage systems for pipes, caged storage for expensive brass and copper items, placement of inventory based on ABC analysis. Separate Location was created for market-return stock. Pipes were stored vertically in a bin, and Mezzanine floor was created to optimize space utilization.

Automation initiatives: WMS and TMS to the rescue. As operations are 100% Box-in and Piece-Out, and inventory size ranged from a small nut to huge pipes, WMS helped to accurately pin point the location and its quantity. New WMS was linked to integrated with the company’s Tally software Leading to smooth process and documents flow.

Inventory Management: A Number of processes and quality check points where implemented and special focus was made on the market return products. Daily and Weekly cycle counts are implemented leading to minimal to no discrepancy in physical and system stock.

Success:

• Improved inventory flow
• 24 hours TAT of delivery of goods as location of inventory became easier
• Lower market returns (SRN) on account of improved inventory flow
• Optimization of space utilization
• Higher manpower productivity
• Immediate attention to SRNs
• Efficient storage of inventory based on requirement as accurate inventory was visible in system

We strongly believe & execute our ideology “Success is the sum of Small efforts - repeated day in & day out”.