In the last Month we had done the following fine tuning the operations:

Implemented the KRA:

First Time @ Akzonobel, Madurai, the roles and responsibilities of each staffs are
explained to them very clearly and got the signature on KRA, from them, So that they
are very clear about their boundaries.

Duty Roaster.

We are getting more CI, Material interchanges at the operations. To understand the
root cause, we had started to observe the activities. In general, in the evening time
only, we used to get more delivery orders.

After 10:00 PM only one supervisor would be in the duty. During month end and
peaking day, the work load was hectic. So this is the one of the reason for the
mistakes.

To avoid that, we had changed the duty roaster, in a such a way that, after 10:00 PM
2 supervisor would be in the duty. This will help and ease them to control the work
pressure, mistakes, Documentation and handing over to transporter.

Despatch Policy.

The new Despatch policy was introduced, to ease of verification and to eliminate the
mistakes.

As per the new policy, the person( 1st supervisor) who checked the Pick has to do the
Video capture after the invoice verification.

The second supervisor has to do the final invoice verification along with the marking
of delivery details on the product like customer details, no of Boxes, etc

By this action the work load was equally shared by the both the supervisors for the
particular delivery.

Inventory Arrangement:

Now we are religiously following the inventory as in the FEFO method which is
important for the Akzonobel policy.
Currently we have prepared a plan for cycle count, which will complete the all the
sku with in a month to the max. In this model, today night itself, the list will be issued
for the pre arrangement for the cycle count, as Sound stock, OL6, OL5 OL3 etc.... So
the next day, the morning shift supervisor will do the cycle count in a prompt
manner. For this purpose a monthly level plan will be prepared on the date wise.

As of now, we are doing the put-away for the refinish material, because, the existing
union offloading team is not up to the mark in put-away of refinish items and their
put-way method is creating the great confusion in retrieving / picking the material.

In initial stock handing over, there was a shortage of 1734 and as of now the variance
is 434 qty.

Point to be Highlighted,

WMS Implementation:

Due to the complexity and similarity the SKU code no pattern or structure, it is very
easy to get confuse and do the mistakes in verification at inward and outward. To
eliminate such mistakes, we need to have WMS system with the Barcode scanner.

By this WMS implementation,

 Improved Inventory accuracy.

 The human depended activities will be changed to system depended.
 Moving towards more process oriented
 Ease to maintain the FEFO, batch details.
 Highly minimised loss / deviation.
 Keeps the client as happy.
 Ease to expand the business with the existing and New client also bcos, this
warehouse will be in a Bench Mark.
 The return of investment in WMS will be in very short, because, retain of the
existing customer and to attract the new customer is could be a simple task

The Manpower Rotation.

At Akzo Nobel, Madurai, the past history had quick man power rotation. Due to this,
after the training / with in short period, if the man power leaves from us, then it is a
small setback for the operations. To avoid this we need a HR Plan to retain the good
manpower and need a back up for the each department.
Put-away Plan at Old warehouse and New warehouse.

As of now we are using the trade union manpower to off-load and do the put-away.
This team is not up to the mark in the offload and put-away.

In this matter, now we are training our own Hindi Pickers team for the receiving and
do the put-away at new warehouse.

At the same time, at the new warehouse, seems, the trade union is too strong. So
they enter in to the off load, the off load rate may go up and they won’t do any put-
away as like now. They may just off-load the material without segregating it and then
we need do to the put-way. This will increase the cost.

To avoid this, we had asked Mr.Pillai and he also agreed to give documents for the
existing hindi pickers, like identify card, ESI, PF Nos.

So that, if the Trade union people come for the Off-load request, we may have point
to stop them at the gate by show those documents at them and may tell them that,
those people are our staffs and trained for the off-load and do the put-away. They
are capable to maintain the stock as FEFO as per our requirement, which they can’t
do.