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TITLE: SPACE UTILISATION CONSOLDATION PERCENTAGE OF EMPTY BINS BIN CAPACITY

RATIONALE OF THE STUDY:

o o o o

Effective use of the available space for better functioning of the processes in the warehouse. Consolidation of articles in different bins. Maximum utilization of bin capacity. Total percentage of empty bins.

INTRODUCTION:

RDC warehouse contains 51,589 bins which are to be utilized to the full extent for the effective functioning. Total area of the warehouse is 1,52,000 sq.ft. This should be properly utilized. For an ideal warehouse the percentage of empty bins should be 20% which should be maintained at rdc. Consolidation of articles helps in carrying operations easily.

IMPORTANCE OF THE STUDY:

Space utilization is the crucial aspect in the functioning of a warehouse, the proper utilization of space helps in improving the accommodation capacity. The percentage of empty bins helps in systematic functioning of the warehouse. Consolidation of the articles helps in producing more space. Maximum utilization of bin capacity helps in reducing the wastage of space

NEED FOR THE STUDY:

Effective space utilization is very much useful in utilization of the available resources to a full extent. Consolidation, increasing the percentage of empty bins and utilization of bin capacity contribute in achieving maximum utilization of the available space

OBJECTIVES OF THE STUDY:

o o o o

To understand the operational functions keenly. To suggest any further improvements for better functioning. For observing flaws in the process. For betterment of functioning process.

SCOPE OF THE STUDY:

It helps in identifying the elements that result in the reduction in the capacity of the operation functions like put away, picking etc... Helps in providing a clear picture of the functions.

RESEARCH METHODOLOGY:

o o o

Information from the staff on the process being followed. Data of stock balance on the daily basis from WMS. Data from inventory cycle count.

LIMITATIONS OF THE STUDY:

o o

Only RDC warehouse is available for study. Manual errors occur frequently.

OBSERVATIONS: LOCATION MASTER BIN TYPE Category Fashion Sub Cat Apps Section Kids Ladies Mens Home Fashion 33880 Footwear GM Footwear Crockery Depot Luggage Plastic Toys and Sports Utensils Grand Shelving Decking Racking Total 7112 78 312 7502 8792 8792 17976 112 553 18641 2496 2686 1724 1339 605 1326 756 1988 4340 38220 960 36 5990 8676 881 1746 512 454 573 1088 320 2947 4693 3377 38312 2236 1793 1596 1178 2414 2036 2024 13277 51589

Home Fashion Fashion Total GM

1596

GM Total Grand Total

RDC warehouse contains 51,589 bins which are to be utilized to the full extent for the effective functioning. Total area of the warehouse is 1, 52,000 sq.ft. This should be properly utilized. As mentioned in the above table the total number of bins in shelving are 38220, decking are 8676, racking are 4693. Major portion of the space is occupied in shelving especially by apparels. Hence the space utilization of bins in shelving is important. The utilization of the bins to the full extent is possible by consolidation of the bins containing same articles.

CONSOLIDATION
Consolidation is the act of merging items of same article number located in different bins. Consolidation process is carried out by the respected LOBs of the departments according to the need and availability of man power. Consolidation process helps in increasing the number of empty bins hence making it easy for the operations process to be carried out.

PERCENTAGE OF EMPTY BINS


As on 23rd of July the percentage of empty bins are as follows.
23.06.11 Family Books Crockery Footwear Home Fashion Kids Type Shelving Decking Racking Decking Racking Decking Racking Decking Racking Shelving Shelving Decking Racking Decking Racking Shelving Decking Racking Decking Racking Decking Racking Occupied 824 929 213 773 372 1654 196 73 120 8115 8133 95 65 75 424 13683 822 961 522 235 286 63 38633 Non Occupied 660 410 235 873 212 927 102 5 192 1937 1611 191 511 1 168 2865 440 293 438 85 86 49 12291 Grand Total 1484 1339 448 1646 584 2581 298 78 312 10052 9744 286 576 76 592 16548 1262 1254 960 320 372 112 50924 Occupied % 56% 69% 48% 47% 64% 64% 66% 94% 38% 81% 83% 33% 11% 99% 72% 83% 65% 77% 54% 73% 77% 56% 76%

Ladies Luggage Mens

Plastics Toys and Sports Utensils

Grand Total

The above table provides the details of empty bins available.76% of the bins are occupied and out of this the percentage of bins occupied in the shelving are about 82% and 18% of the empty bins are available in the shelving area. For an ideal warehouse a minimum of 20% of the empty bins are to be available for the proper functioning of the process.

Apps Clothing Status of RDC Bangalore Family Capacity Defined Non Prepack Prepack 54875 Total BOH qty % Utilization Count of SKU

Mens Ladies Kids Home Total Apps

493,025 527427 319,860 393206 369,600 351188 210,880 172860 1393365 1444681

582302 443391 50185 489248 138060 172860 243120 1687801

118% 6204 139% 5463 132% 5799 82% 1644 121% 19110

The above table explains the utilization of the capacity. Apparels occupy more space than the defined, hence are to be more concentrated.

BIN CAPACITY:
The total bin capacity in shelving is 141506.106 sq ft. Out of which the capacity of the bins varies among different bins.

Volume(sq ft) 2.88 2.882 3 3.24 3.6 4.318 5.76 5.763 8.637

count 526 9794 1709 15352 1653 3347 428 3256 1772

Sum(sq ft) 1512 28223.426 5124 49737.24 5947.2 14448.028 2459.52 18758.565 15296.127

% of bins 1.06 19.94 3.6 35.14 4.2 10.2 1.738 13.256 10.8

At RDC warehouse the he boxes are directly put into the bins hence preventing the total usage of the bins. The average of the bins is taken as 3.24 sq ft and accordingly the capacity is calculated.

RDC
INBOUND
OUTBOUND INVENTORY MANAGEMENT RETURNS

ORDER PROCESSING, PRE RECEIVING ALLOCATION & WAVE CREATION

WAREHOUSE TO WAREHOUSE TRANSFER

RTV -SAP INITIATED

RECEIVING

CLUSTER PICKING

REPLENISHME NT

RTV-WH INITIATED

PUTAWAY BATCH PICKING

CYCLE COUNTING

RETURN TO WARE HOUSE FROM STORE

CROSS DOCK

HUB & RDC(OWNER TO OWNER TRANSFER)

RETURN TO WARE HOUSE FROM STORE(FULL TRUCK LOAD)

LOADING & SHIPPING

INVENTORY MOVES

BALANCE ON HAND

1. Inbound
1.1. Pre Receiving 1.1.1 Pre Receiving (From Vendor) Process Description: Pre Receiving process will enable warehouse to unload the consignment and
release transporter WMS imports PO, Inbound details from SAP Update date & time for ASNs ( either through inbound or by calling up the vendor from warehouse) Warehouse will have daily report of scheduled ASNs for the day Vehicle arrives at the gate of the warehouse. Truck driver submits the document to the security personnel PO , LR , Invoice, Inbound Copy, Quality report. Security verifies the documents and checks if the consignment is for the same warehouse. Security personnel write details in security inward registerKey Fields: Inward Date/Time, Truck No., LR Number, PO Number/Date, ASN Number assigns manual inward number. Driver submits the documents to inward clerk Inward clerk checks all documents for any discrepanciesPO and ASN are matching or not Invoice is correct ASN is created or not LR details is correct Inward Clerks recalls ASN number in WMS screen and updates detailsKey Fields: LR Details, Transporter code, Vehicle number, Number of boxes mentioned on LR, Dock Door Inward clerk assign available dock door manually and instruct driver to proceed for unloading. Driver parks the vehicle at the assigned dock door for unloading. Inward staff starts unloading activity While unloading inward staff weighs the carton(s) for LR weight verification if required and move the consignment to pre-receiving area. Inward staff segregates the all cartons based on ASN & keeps them on pallet in a lane/lanes (Pallet id validation based on pallet 10 digit numbering model: PL-10-999999 [Pallet (2 digit)-Warehouse (2digit)-No. Series (6 digit)] Inward staff starts scanning in RF Key Fields: ASN, , Lane id, Pallet Id

Inward staff counts & enters the number of boxes on pallet on RF screen Inward staff enters the count of damaged boxes on pallet on RF screen (if any). Once all the pallets are scanned, Staff confirms on RF (IGP generation screen) that scanning is over Inward clerk generates gate pass from WMS based on above confirmation. This will trigger IRN in SAP Inward clerk handover the gate pass to driver. Driver report back to Security personnel Security personnel update the security register. Key Fields: Gate Pass Number & Truck out time against the ASN number. SAP to send IRN host reference detail to WMS.

Exception Handling:

In case consignment is not for the warehouse then Security personnel will not allow truck to inward If inbound is not created for that consignment then truck will not be allowed to unload. Further category to be informed to create ASN While unloading if any of the carton(s) found tampered/ damage, has to be kept aside on a seperate pallet with ASN number mentioned on it for transporter damage process handling If document details are not matching then inward in- charge will take appropriate action

Business Rules:

One ASN = One Gate Pass Any delivery received without ASN, PO and Invoice will be rejected. Gate pass would not be generated until Pre- receiving is confirmed for complete IGP once printed cannot be changed. IGP created in WMS will flow to SAP for IRN confirmation.

Pre-receiving process (From Vendor)


SAP Inbound Start IGP generation

WMS imports PO /Inbound Details from SAP

WMS generates ASN against the Inbound

Refer Chapter 4.1.2/ Refer Chapter 4.1.2/ Fig. No. 104/Page 90 Fig. No. 104/Page 90 of WMS User manual of WMS User manual

Appointment to be given on the Appointment to be given on the basis of W/H unloading capacity/ basis of W/H unloading capacity/ day/shift day/shift W/H to define a cut off time for W/H to define a cut off time for servicing vendor vehicles servicing vendor vehicles

Calls up the Vendor for giving appointment Calls up the Vendor for giving appointment and updates appointment and LR details in and updates appointment and LR details in WMS against the ASN WMS against the ASN

SCM Team SD Team

Refer Chapter 4.1.3/Fig. Refer Chapter 4.1.3/Fig. No. 106/Page 91 of WMS No. 106/Page 91 of WMS User manual User manual

Generate Schedule ASN report from WMS for the day at the start of the shift. Take print out of the report and mail the soft copy of the report to Inward security team.

Vehicle arrives at main gate. Driver reports to security with consignment documents

Note set of document Note set of document contains PO, ASN, Invoice, contains PO, ASN, Invoice, and LR copy, Quality Report ( and LR copy, Quality Report ( In case of Apparels) In case of Apparels)

Security

Send the vehicle back

No

Check whether the Consignment is meant for the Warehouse by checking warehouse site code/ address in PO

Security

Security

Inform to SCM Inform to SD Team

End Check whether an appointment has been given to the vendor vehicle (Schedule ASN report)

No No

Yes Yes

Hold the vehicle and inform SCM and inform SD person

Security

SD person to Check whether the vehicle can be unloaded in consultation with Inward Incharge during the day/shift Send the vehicle back and inform category team via mail

Yes

Security Inform the truck driver about the probable unloading time

Hand over documents to Inward In-charge

No

Inward In-charge

Check for any document Discrepancies i.e. LR, Vendor Invoice, PO, Inbound copy and QI Report

NO

End Yes Yes

Inward In-charge informs driver that goods can not be inwarded

No

Can document discrepancies be managed

Inward In-charge

Inward In-charge Inform SCM Inward In-charge Inform SD person

Yes

SCM person is to resolve the SD person is to resolve the issue issue

Manage the Document Discrepancies

Refer Chapter 4.1.4/Fig. Refer Chapter 4.1.4/Fig. No. 110/Page 94 of WMS No. 110/Page 94 of WMS User manual User manual

Inward In-charge updates ASN with LR details & assigns the dock

Note input details Note input details Transporter Code, LR Number, Transporter Code, LR Number, LR Date and Expected Number LR Date and Expected Number of boxes, Vehicle Number of boxes, Vehicle Number against each ASN against each ASN

Pre-receiving process (From Vendor) A

Hand over documents to Security

Inward In-charge

Directs driver to dock the vehicle as per the assigned dock door

Security

Assigns token no. to the vehicle, mentions the token no. on the Inward register, enters consignment details in Inward register

Security

Stamps the vehicle detention seal on the back side of LR

Security

Mentions the reporting time & date on the seal

Security

Enter the Details of vehicle reporting in Inward register

Security

Direct labours to off-load the vehicle

Inward In-charge

Place the boxes on the pallet and move the pallet to pre-receiving staging area

Inward Staff

One Pallet = One ASN. Do not place carton of different ASN on one Pallet

Segregate the boxes ASN wise on Pallets

Inward staff

Pre-receiving process (From Vendor) B


Refer Chapter 4.1.5/Fig. No. 112/Page 95 of WMS User manual

Log in WMS RF Device

Inward Staff

Refer Chapter 4.1.5/Fig. No. 115/Page 97 of WMS User manual

Scan ASN No. bar code printed on Scheduled ASN Report in RF

Note scanning details ASN, Lane no, Pallet id

Refer Chapter 4.1.5/Fig. No. 116/Page 97 of WMS User manual

counts the no. of cartons kept on the individual pallet for that ASN

Inward Staff

Enter no. of damage cartons in RF

Damage Carton

Condition of Carton

Ok carton

Refer Chapter 4.1.5/Fig. No. 116/Page 97 of WMS User manual

Enter the total No. of carton kept on the pallet in RF Handover the damage carton to vendor transporter Inward Incharge

Inward staff

Complete all the pallets for that ASN


Yes

No

Mention the damage carton detail in gate pass

Inward Incharge

Inward In-charge generates the IGP (Inbound gate Pass) Mail the details to Vendor with CC to FSCS SCM Inward Incharge

Refer Chapter 4.1.6/Fig. No. 121/Page 100 of WMS User manual

Take print out of IGP ( 2 Copies)

Inward Incharge

End

Handover 1 IGP copy to driver and attach one copy with consignment document and file it

Inward Incharge

Reports back to security at Gate and Handover Gate Pass to security

Truck Driver

Update the Security Inward Register Stamp the Inward seal on the LR (consignor & consignee copy), enter the details in the stamped portion, Mention the Remark for any Shortage/ Damage sign the same. Handover the transporter LR copy to truck driver and release the vehicle

Security

Security

End

Pre Receiving (From MHUB) Process Description: Pre Receiving process will enable warehouse to unload the consignment and release transporter. WMS imports delivery details from SAP Updates the appointment and LR details in WMS against the ASN on the basis of pre-alerts received from FSCSL transportation Team Warehouse will have daily report of scheduled ASNs for the day Vehicle arrives at the gate of the warehouse. Truck driver submits the document to the security personnel STN, LR, Gate Pass Security verifies the documents and checks if the consignment is for the same warehouse. Security personnel write details in security inward registerKey Fields: Inward Date/Time, Truck No., LR Number, PO Number/Date, ASN Number assigns manual inward number Driver submits the documents to inward clerk Inward clerk checks all documents for any discrepancies Inward Clerks recalls ASN number in WMS screen and updates detailsKey Fields: LR Details, Transporter code, Vehicle number, Number of boxes mentioned on LR, Dock Door Inward clerk assign available dock door manually and instruct driver to proceed for unloading. Driver parks the vehicle at the assigned dock door for unloading. Inward staff starts unloading activity While unloading inward staff weighs the carton(s) for LR weight verification if required and move the consignment to pre-receiving area. Inward staff segregates the all cartons based on ASN & keeps them on pallet in a lane/lanes (Pallet id validation based on pallet 10 digit numbering model: PL-10-999999 [Pallet (2 digit)-Warehouse (2digit)-No. Series (6 digit)] Inward staff starts scanning in RF

Key Fields: ASN, , Lane id, Pallet Id Inward staff counts & enters the number of boxes on pallet on RF screen Inward staff enters the count of damaged boxes on pallet on RF screen (if any). Once all the pallets are scanned, Staff confirms on RF (IGP generation screen) that scanning is over. Inward clerk handover the gate pass to driver. Driver report back to Security personnel Security personnel update the security register. Key Fields: Gate Pass Number & Truck out time against the ASN number. SAP to send IRN host reference detail to WMS.

Exception Handling: In case consignment is not for the warehouse then Security personnel will not allow truck to inward. If inbound is not created for that consignment then truck will not be allowed to unload. Further category to be informed to create ASN. While unloading if any of the carton(s) found tampered/ damage, has to be kept aside on a seperate pallet with ASN number mentioned on it for transporter damage process handling. If document details are not matching then inward in- charge will take appropriate action.

Business Rules: One ASN = One Gate Pass Any delivery received without ASN, PO and Invoice will be rejected. Gate pass would not be generated until Pre- receiving is confirmed for complete IGP once printed cannot be changed. IGP created in WMS will flow to SAP for IRN confirmation.

Pre-receiving process (From MHUB)


SAP Inbound Start IGP generation

WMS imports Deliveries Details from SAP

WMS generates ASN against the Delivery

Refer Chapter 4.1.2/Fig. No. 102/Page 89 of WMS User manual

Updates the appointment and LR details in WMS against the ASN

SCM Team

Refer Chapter 4.1.3/Fig. No. 106/Page 91 of WMS User manual

Generate Schedule ASN report from WMS for the day at the start of the shift. Mail the soft copy of the report to Inward security team.

Vehicle arrives at main gate. Driver reports to security with consignment documents

Note set of document contains STN and LR copy, Gate Pass

Security

Send the vehicle back

No

Check whether the Consignment is meant for the Warehouse by checking warehouse site code/ address in STN

Security

Security

Inform to SCM Team

Yes

End

Hand over documents to Inward Incharge

SCM Team

Inward In-charge

Check Whether the driver is carring STN and LR,

Yes

No
No LR

No STN

Ask the truck driver to get the LR details

No

STN No. mentioned on LR

Yes

Take the STN details from the Shipping warehouse

Check the delivery details in SAP

Refer Chapter 4.1.4/Fig. No. 110/Page 94 of WMS User manual

Inward In-charge updates ASN with LR details & assigns the dock

Note input details Transporter Code, LR Number, LR Date and Expected Number of boxes, Vehicle Number against each ASN

Pre-receiving process (From MHUB) A

Hand over documents to Security

Inward In-charge

Directs driver to dock the vehicle as per the assigned dock door

Security

Assigns token no. to the vehicle, mentions the token no. on the Inward register, enters consignment details in Inward register

Security

Stamps the vehicle detention seal on the back side of LR

Security

Mentions the reporting time & date on the seal

Security

Enter the Details of vehicle reporting in Inward register

Security

Direct labours to off-load the vehicle

Inward In-charge

Place the boxes on the pallet and move the pallet to pre-receiving staging area

Inward Staff

One Pallet = One ASN. Do not place carton of different ASN on one Pallet

Segregate the boxes ASN wise on Pallets

Inward staff

Pre-receiving process (From MHUB) B

Refer Chapter 4.1.5/Fig. No. 112/Page 95 of WMS User manual

Log in WMS RF Device

Inward Staff

Refer Chapter 4.1.5/Fig. No. 115/Page 97 of WMS User manual

Scan ASN No. bar code printed on Scheduled ASN Report in RF

Note scanning details ASN, Lane no, Pallet id

Refer Chapter 4.1.5/Fig. No. 116/Page 97 of WMS User manual

counts the no. of cartons kept on the individual pallet

Inward Staff

Enter no. of damage cartons in RF

Damage Carton

Condition of Carton

Ok carton

Refer Chapter 4.1.5/Fig. No. 116/Page 97 of WMS User manual

Enter the total No. of carton kept on the pallet in RF Handover the damage carton to vendor transporter Inward Incharge

Inward staff

Complete all the pallets for that ASN


Yes

No

Mention the damage carton detail in gate pass

Inward Incharge

Inward In-charge generates the IGP (Inbound gate Pass)

Refer Chapter 4.1.6/Fig. No. 121/Page 100 of WMS User manual

Mail the details to Vendor with CC to FSCS SCM

Inward Incharge

Take print out of IGP ( 2 Copies)

Inward Incharge

End

Handover 1 IGP copy to driver and attach one copy with consignment document and file it

Inward Incharge

Reports back to security at Gate and Handover Gate Pass to security

Truck Driver

Update the Security Inward Register

Security

Stamp the Inward seal on the LR (consignor & consignee copy), enter the details in the stamped portion, Mention the Remark for any Shortage/ Damage sign the same. Handover the transporter LR copy to truck driver and release the vehicle

Security

End

Receiving:
Receiving process enables to receive consignment and update warehouse inventory status and GRN in SAP. Inward in charge handover pending receiving pallet movement report to inward team. Key Field :ASN number, Lane/Pallet id, Number of boxes Inward team brings pallet as per the pending receiving pallet movement report at the receiving bay. Inward team segreagate the stock as per SKU . Team opens the cartons(s) to verify quantity received 1. Sample Verification will be done as per vendor No validation in system on Verification based on vendor classification Inward team place carton on weighing machine and paste weight label on the box Verification process:(One box per SKU should be verified, Scan a SKU &Count all SKUs for a box) Single SKU Carton(s): Check if any carton(s) found with weight variance, Open the boxes and count the SKU If discrepancy found treat those box as rejected and keep them aside (Specific location for excess/ damage receive) *refer exception process flow If no discrepancy found then receive the carton. Multi SKU Carton(s): No weight verification, Qty Verification to happen while scanning. Scan/ Count all articles for receiving If exception found, Keep excess/ damage SKUs aside If no then receive the SKUs Receiving Single SKU UOM on pallet : Scan EAN Put boxes on pallet & count qty. as per order UOM Enter qty. & scan the pallet

Receiving Single SKU UOM in box : Take new box & paste box id Scan EAN Put SKU in Box & count qty. as per order UOM Enter qty. & scan the box id.

Receiving Multi SKU carton : Need to prepare separate SKU wise box : Take new box & paste box id Scan EAN Put SKU in Box & count qty. as per order UOM Enter qty. & scan the box id.

NO Need to prepare separate box : If the box id not present then paste a new box id on Box If each piece scan option is opted then , o Scan/Enter ASN o Scan box id o Scan all EANs If each piece scan option is not opted then, o Scan/enter ASN o Scan EAN o Count & enter qty. Scan box id. Inward team informs inward in-charge that receiving process is completed for one ASN Inward In-charge verify the receiving against ASN If shortage is there then inward incharge selects the correct reason code at ASN line level. Inward in-charge generates the GRN after closing ASN. This will create GRN in SAP. In case of single SKU/ Multi SKU boxes in the same ASN; 1. For all single SKU Boxes: Follow process#7 Receiving Single SKU UOM on pallet 2. On RF, Change the option to Each Piece Scan 3. In each piece scan option o Scan/Enter ASN o Scan box/pallet id o Scan all EANs Other Option of scan EAN & enter count of Qty can also be used.

Exception Handling: Receiving excess or damage from vendor: Create new ASN with reference to original ASN Do receiving as per standard process. Do GRN and move the stock to relevant location using RF. This will not update SAP. In the rare of own transport Delivery shortage ZSIT will be made in SAP by warehouse team. In WMS GRN will be made only to the extent of the physical receipt of the goods Business Rule: One ASN = One GRN = One Invoice WMS to disallow receiving more than expected qty mention in ASN. There will not be vendor tolerance validations against the PO for ASN while receiving. In case of any discrepancy found then entire case to be rejected while receiving Single SKU carton. In case of any discrepancy found then entire case to be rejected while receiving Single SKU carton. Receiving to be done as per mentioned UOM in ASN. Excess/Damage ASN will have link with original ASN Pending receiving report will print those ASNs for which IGP has been made and receiving has not been started. WMS to capture reason for Short receive. New Inbound will be created in case of Excess Receiving from vendor with the reference of old Inbound. SAP to capture old inbound number GRN reversal will not be allowed in WMS. WMS will do pre-allocation as soon as GRN is completed in case of vendor ASN receiving WMS will send pre-allocation data to SAP for soft allocation. Incase of PO is blocked in SAP; WMS should not be able to receive against it. WMS to Capture ASN number in lottable 2 for GRN made. SAP to Send GRN HOST reference along with SKU and MAP details to WMS for each GRN made.

Receiving process
Pallet moving to pending for receiving area

Start

GRN

Refer Chapter 4.2.1/Fig. No. 126/Page 105 of WMS User manual

Generate Pending Receipt Pallet Movement Report at the start of the shift and take print out of the report Select the consignment to be moved by checking the ASN no. for that consignment in the pending receipt pallet movement report Look for the pallets having the pallet ID mentioned in the pending receipt pallet movement report against the given ASN

Report to Print All ASN Details for which Gatepass is generated and Receiving is not started

MHE Operator

MHE Operator

MHE Operator Pallet scanned belong to selected ASN


No

select another Pallet ID

Yes

Move pallet to pending receiving staging area with the help of BOPT/HPT

MHE Operator

Complete scanning/movement of all the Pallet for that ASN

MHE Operator

No

Scanning/ pallet moving task of all the pallets belonging to one ASN completed
Yes

Yes

Is there any other Consignment/ASN to be moved to pending prereceiving staging area


No

Inform Inward incharge

MHE Operator

Inward incharge to Hand over the documents corresponding to ASN for which the receiving activity has to be started to the receiving team

Inward In charge

Note : Ensure that all the boxes belonging to one SKU is kept on one pallet

Segregate boxes SKU wise for the ASN for which the receiving activity has to be started

Receiving Team

Receiving process A

Count quantity Packed Quantity

Open one carton of a SKU, to verify the qty recieved


Count Quantity = Packed Quantity

Receiving Team

Place carton on weighting M/C and paste weight label on carton

Receiving Team

Place another carton of same SKU on weighting M/C


RTV Process

Receiving Team

Carton is rejected and kept aside (Refer Note)

Weight of the carton tallies with the SKU weight of verified carton

Note : Exception : (Excess / Rejected) 1. Open New ASN for Excess / Damage Receive 2. Receive excess or Damage SKU / Carton in this New ASN 3. Keep the received ASN at specified location (Refer Exception process flow)

Process ends

Yes No

Verification for all the cartons belonging to that SKU complete

Yes

Take another SKU for that ASN

Receiving Team

No All the SKU for ASN Verified

Receiving process B
No

Refer Chapter 4.2.2/Fig. No. 130,131/Page 108 of WMS User manual

Check receiving condition Inward staff Receiving multi SKU Cases (As per UOM)

Receiving single SKU Cases (As per UOM)

Pallet

Receive in?

Cases

Inward team member takes new box & pastes box id Inward Scanner

Yes

Segregate SKUwise as per Order UOM

Scan EAN, Put box(s) on pallet and count qty as per order UOM Enter Qty and Scan pallet

No

Scan EAN, Put SKU in Box and count qty as per order UOM Enter Qty and Scan Box id
Refer Chapter 4.2.2/Fig. No. 130,131/Page 108 of WMS User manual

Yes

Check box id presence Inward Scanner

Inward Scanner Inward Scanner

No Each Pcs Scan Paste box id on carton

Yes

Refer Chapter 4.2.2/Fig. No. 130,131/Page 108 of WMS User manual

Enter/Scan ASN, Scan Box id, and Scan all EANs

No Enter/Scan ASN, EAN,

Inward Scanner

informs inward incharge that Receiving process complete for one ASN Inward Scanner

Inward Scanner Enter Qty and Scan Box Id

Receiving process
Refer Chapter 4.2.4/Fig. No. 145/146,147,148/ Page 91 of WMS User manual

Do receiving as per applicable receiving process

Create New ASN with ref to original ASN

Yes

Excess/ Damage Rejected Receiving?

No

Inward in-charge to close ASN and move the stock to relevant location using RF by scanning box ID/pallet ID and Location ID

This ASN & GRN will not flow back to SAP.

Once Receiving is complete for one ASN, Inward incharge verify for ASN to be closed

Refer Chapter 4.2.5/Fig. No. 150,151/Page 121 of WMS User manual

Excess Stock will either be Return through RTV (1) or Stock adjustment Against Fresh ASN (2)

1. Refer RTV process WH initiated 2.Refer Excess Regularization process

Shortage

Yes

Inward incharge selects the correct reason code at ASN line level

No

End

Refer Chapter 4.2.5/ Fig. No. 156/Page 124 of WMS User manual

Inward in-charge Close ASN for GRN output

GRN Report Out Put with Discrepancy -Auto Mail to Vendor

Give reference of GRN number on Invoice copy and file the LR, vendor Invoice copy, Inbound copy, PO and QC Inspection Report, IGP

Inward Team

Refer Merchandise Documents Movement process

Invoice Submission to FKSL (Future Knowledge Service Ltd.) Ahmedabad

Give GRN Number and Date to security

Inward Team

Note down GRN number and date in the Inward Register against the IRN details of the consignment End

Security

Vendor Excess Receiving against fresh ASN

Process Starts
Refer Chapter 4.2.4/Fig. No. 145/Page 118 of WMS User manual

Create new ASN in WMS.

Refer Chapter 4.2.4/Fig. No. 146/Page 119 of WMS User manual

Enter the owner number (0101), select the type of ASN as vendor WH ASN and save the data

Refer Chapter 4.2.4/Fig. No. 146/Page 119 of WMS User manual Refer Chapter 4.2.4/Fig. No. 146/Page 119 of WMS User manual

In general Tab enter warehouse site code in UDF 1,

Enter the ASN no in which the excess was found as reference in UDF 4

Refer Chapter 4.2.4/Fig. No. 146/Page 119 of WMS User manual

Enter the Vendor code from whom the Excess quantity is received in UDF 2

Refer Chapter 4.2.4/Fig. No. 147/Page 119 of WMS User manual

Enter the article code for which excess is received from vendor in Item tab

Refer Chapter 4.2.4/Fig. No. 147/Page 119 of WMS User manual

Enter the excess received quantity in Expected quantity tab

Refer Chapter 4.2.4/Fig. No. 147/Page 119 of WMS User manual

Select drop down for Location tab and select STAGEEXCES as location and save the detail

Refer Chapter 4.2.4/Fig. No. 148/Page 120 of WMS User manual

Enter new for next line article ( if any ) in the same ASN (or else exit)

This triggers a new ASN in WMSwhich has reference of original ASN.

Refer receiving process

Do receiving against new ASN. Receive the material in location stage excess " Move " the stock from location " STAGEEXCES " to location in special zone created for vendor excess material ( with help of HHT )

Map the article and appropriate quantity to particular location

Process end

1.1.

Put away

PUTAWAY process enable to place received consignment in the respective location considering Space Optimization, Minimum Effort and With SKU/ MC Consolidation Process Steps: Based on load Put away member decides move the items to bulk location or normal Putaway location. BULK location: Log on to RF & Select the MOVE option Manually move the pallet to bulk location

Scan location and pallet id Normal putaway location: Put away team member scans the pallet or box id. System guides to IN location for put-away zone In case of put away for 1st or 2nd floor of mezzanineThe IN location is defined on ground floor separately for 1st & 2ndFloor. The Put away team member will leave the pallet at the respective IN locations of 1st & 2ndFloor and scan to confirm. Put away reach truck member to scan box id or pallet id to confirm the floor and will move physically to respective Floor of Mezz. Bin Management team moves the pallet to final location based on put away strategy suggested by system. (Follow normal process steps to confirm put away) If suggested location is non mezzanine then, User moves pallet to IN location and scan IN location for confirmation User open put-away option in WMS Bin management team scans Pallet id/Box id and SKU from IN location System guides the put-away location based on the put-away strategy of the SKU & WMS also to suggest quantity of SKU User goes to system suggested specific location confirm by scanning the location and qty placed Follow the process until receiving bay and IN location is empty

Assigning Put Away Strategy to SKU:


WMS WMS Interface

Zone
Zone 1 Zone 2

Fixed pick
FP1 FP2

Strategy
Strategy1 Strategy2

SKU
Sku1 Sku2

Zone
Zone 1 Zone 2

Fixed Pick
FP1 FP2

Every fix pick will be associated to Zone. This will be stored in SKU-Zone table. (In case of new SKU without dimension data, warehouse to update the dimension data before put away.) Every Zone will have default put away strategy. This will be stored in put away strategy table. Fixed Pick to be defined for all SKUs created in WMS. (Excel Upload) Once the article is created in WMS, default putaway strategy will be attached to that SKU based on fix pick location & corresponding zone.

Exception Handling: If Bin management team member enters Qty. different than suggested then, Capture correct reason code WMS to trigger cycle count for a specific reason.

Business Rule: Putaway will not take place unless GRN is done For items with fixed-pick locations, Put away will always be to reserve locations except when the balance stock of that SKU in warehouse is zero. Put away team member must ensure that different floors/sections items are not placed on pallet.

Put-Away Strategy:

Strategy 1 - No fixed pick location, Do not mix MC, Mix SKU Put away strategy for items in specified zone Search for same SKU, search for capacity available more then or equal to put away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from location with exact fit) Search for EMPTY Location, If found WMS to suggest that location Search for same SKU, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty) Search for Different SKU in same MC, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty) WMS to suggest UNKNOWN location

Strategy 2 - Pick location Fixed by SKU, Reserve Mix SKU, Do not mix MC

If balance qty in specified Zone (as mention in strategy) is equal to zero WMS to suggest the Fixed Pick Location

If balance qty in specified Zone (as mention in strategy) is not equal to zero Search for same SKU, search for capacity available more than or equal to put-away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from nearest location based on co-ordinates) Search for Different SKU, search for capacity available more than or equal to put-away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from nearest location based on co-ordinates) Search for EMPTY Location, If found WMS to suggest that location Search for same SKU, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty starting from nearest location based on co-ordinates)

Search for Different SKU in same MC, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty starting from nearest location based on co-ordinates) WMS to suggest UNKNOWN location

Strategy 3 - Fixed pick location, Do not mix MC, Do no mix SKU

If balance qty in specified Zone (as mention in strategy) is equal to zero WMS to suggest the Fixed Pick Location

If balance qty in specified Zone (as mention in strategy) is not equal to zero Search for same SKU, search for capacity available more than or equal to put-away qty, If found WMS to suggest that location (Fill such locations is ascending order of available qty starting from location with exact fit) Search for EMPTY Location, If found WMS to suggest that location Search for same SKU, search for capacity available, If found WMS to suggest that location (Fill such locations is descending order of available qty starting from location with exact fit) WMS to suggest UNKNOWN location

Documents Used:

List of newly created articles To view the articles for which Fix Pick location/Zone is not defined. (Dashboard)Alert to be given by system for newly created articles.

Put Away
GRN done Start Put Away

Bulk or Normal put away location? Bulk location Normal put away location

Refer Chapter 3.6/ Fig. No. 93/Page 82 of WMS User manual

Put away Team member selects move option in RF

BOPT/HPT Operator

select Putaway option in RF screen

Refer Chapter 5/ Fig. No. 160/Page 110 of WMS User manual

BOPT/HPT Operator

manually moves pallet to bulk location with the help of BOPT

Select IN LOC Move option in Putaway to move Pallets from RECEIVING Location to IN LOCATION

Refer Chapter 5/ Fig. No. 161/Page 111 of WMS User manual

Refer Chapter 3.6/ Fig. No. 96/Page 83 of WMS User manual

BOPT/HPT Operator

Scans the location and pallet id

Scan the LPN number (Pallet id or Box id) to be moved from the Receiving location to the IN Location

Refer Chapter 5/ Fig. No. 163/Page 112 of WMS User manual

Process End System give IN location for that Pallet/Box Id

Move pallet to specified IN Location


In case of the ground floor IN location of MEZ floor 1 & 2, the reach truck will physically put the pallet on to the respective floor from where it will be put-away to the final location

BOPT/HPT Operator

Scan IN location for confirmation

BOPT/HPT Operator

Yes

Another pallet/ Box to be moved

No

Inform to Put away Incharge

Put away In-charge assign Put away task to put away team member

Refer Chapter 5/Fig. No. 164/Page 112 of WMS User manual

Select Assisted PA option in Putaway menu to putaway from IN Location to Fix Pick/Fast Pick Zone

Put away Team Member

Put away team member Scan pallet id/ Box Id and SKU from IN location

Refer Chapter 5/ Fig. No. 166/Page 113 of WMS User manual

WMS to suggest Bin location based on the putaway strategy

Refer Chapter 5/ Fig. No. 167/Page 114 of WMS User manual

WMS to suggest put away Qty

Confirm TO LOCATION by scanning location id by RF or enter the location id and enter Putaway QTY

Put away Team Member

Correct Reason captured

Yes

Qty entered different from suggested?

Note : After Put away of all the articles on the pallet, do Inquiry of the pallet in HHT to verify the same pallet is empty

No

Trigger CycleCount for specific reason

WMS to suggest new task i.e put away of another SKU

1.1.

End

Order Processing, Allocation & Wave Creation


Process Description: Order processing and Allocation process will collect the STO/SO from SAP and will create pick task based on wave schedule. Process Steps

SAP push delivery to WMS as per schedule Delivery Types STO, SO, RTV, Emergency Order , Cross Dock Order Orders get Pre-Allocated once received in WMS based on warehouse stock SAP gets soft commitment once pre-allocation is done in WMS Inventory Not Available in Warehouse:Pre Allocation is not possible due to less inventory, Generate Wave and assign order to wave as per schedule If GRN is done in between, perform pre Allocation and Allocation If GRN is not done then creates back order and wait for inventory for Pre Allocation and Allocation SAP order line will be frozen Pre Allocation done and Allocation Pending But in Wave:Generates Replenishment task Allocation is done Wave is release SAP order line will be frozen. Pre Allocation done and Allocation Pending due to not in the Wave:These orders are included in next scheduled wave for that order. Allocate and Release order SAP order line will be frozen. Wave Picks orders scheduled for the day Based on Store delivery Matrix

Incase over allocation is not turned on (Standard Process); then hard allocation qty will be to the extent of the pick face qty. (i.e. hard allocation qty= Pick face Qty) When Over allocation is turned ON; entire pre allocation qty will be hard allocated based on allocation strategy as follows; o o Fix pick Location: If allocation is allowed from receiving staging, replenishment tasks for fix pick location will be generated from the receiving staging location and also reserve location if stock is stock available. Fix Pick Location: If allocation is NOT allowed from receiving staging, replenishment for fix pick location will happen from reserve only.

o Non Pick Location: Turning on over allocation does not affect such locations. Once the allocation of order is done, WMS to send data to SAP & SAP order line will be frozen. Release the wave and create pick task for the warehouse staff

Processing of order other than normal orders

For Batch Pick Orders : WMS pulls fast moving SKU from SAP order(s) after pre-allocation & creates separate order. Creates a separate wave for these orders. Allocate order based on available stock Release and create Batch Pick Task

Cross Dock :Pre-Allocation and Allocation for cross dock will happen on GRN for that PO. Crossdock order will not have a wave

Order Processing, Allocation & wave creation

Order Processing
STO Types 1. Normal Orders 2. Cross Dock 3. Customer Sales Orders 4. Emergency Orders

Start

Wave creation

Orders Imported from SAP to WMS through BOOMI

Pre Allocation Will happen as soon as Orders are Imported from SAP

No

Pre-Allocation Is Stock Available

Yes
Interface Sent to SAP of Pre Allocation Qty

Pre Allocation is not Done

Pre Allocation of Orders

NO

Wave to Run Check for Scheduled Shipment Date

Wave Is not Generated

Wave to Run as per daily YES schedule Check Orders for Scheduled Shipment Date Generate New Wave Attach Orders No Schedule for Next Wave run

Yes

Generate New Wave Attach Orders

Any GRN for the day

No

Schedule for Next GRN

No

Any GRN for the day

End Yes End Yes


Interface Sent to SAP of Pre Allocation Qty

Allocate Wave Hard Allocation

Yes Cross Dock Order

Pre-Allocate against GRN

Pre-Allocate against GRN

Release Wave Generate Pick Task

Interface Sent to SAP of Hard Allocation Qty

Do Putaway

No

End

Schedule for Next Wave run

End

Store Rhythm Logic:


Pre-Requisite WMS to maintain store wise transit time and processing time for the warehouse. WMS to maintain store wise rhythm days - these are the days on which goods will be shipped. And also to maintain the exclusion list (holidays, sundays etc.) Process SAP will give delivery date for each line item WMS to calculate ideal ship date (i.e. Delivery date - transit Time) If Ideal ship date matches with Store Rhythm day (calendar), then it will be actual shipment date. Else check with the next available rhythm day and get a derived ship date and a derived delivery date for that line item. WMS will give wave processing date. (i.e. Actual Shipment date- Processing days) WMS to send derived shipment date & revised delivery date to SAP. The SLA will be calculated on this derived ship date.

Store Rhythm Logic


Ideal delivery date Actual delivery date

Process starts

1)WMS to maintain storewise transit time & processing time for the warehouse 2) WMS to maintain storewise rhythm dates 3) WMS also to maintain the exclusion list(holidays ,sundays etc)

SAP gives delivery date for each line item in order

This will be termed as an ideal delivery date

Order flows into WMS

Based on ideal delivery date WMS calculates ideal shipment date

Ideal shipment date = ideal delivery date transit time

No

Ideal shipment date matches with store rhythm date

Yes

System checks next available rhythm date & makes it actual shipment date

Ideal shipment date becomes actual shipment date

WMS derives actual delivery date

Actual delivery date = actual shipment date + transit time

WMS derives wave processing date

Wave processing date = actual shipment date processing time

WMS sends actual delivery date to SAP

Process ends

Outward Team In-charge informs respective outward team member for pick task Assign Handheld device to respective team member for picking Picker logs in Handheld device Picker enters the user login id and password and selects cluster picking option User gets default picking area & default sequence of picking. WMS identifies priority order & suggests number of stores for picking based on user selection ( Min-4 , Max.- 6) If picker wants to override then picker updates the stores with reason. Picker picks empty boxes & pastes labels on it. Picker places boxes on the pallet and moves them to picking location assigned WMS suggests 1st pick location, SKU,EAN & number of quantities to be picked. Single SKU Location: Scan the location Count & enter the quantity Place the SKUs in correct box Scan the box id Mix SKU Location :Each piece scan : Scan the location Scan all same SKUs Place the SKUs in correct box Scan the box id

Mix SKU Location :No Each piece scan : Scan the location Count & enter the quantity Place the SKUs in correct box Scan the box id Box filled? If no then picker continues with the next task If yes then picker puts the box in OUT location.

User moves the pallet to consolidation location. User logs onto RF & selects the packing option. Packer scans the box id & measures & inputs the weight. WMS Prints Shipping Label & Packing List (optional) User pastes shipping label on box Packer puts the BOX on fresh Pallet & Scans the Shipping label & Pallet ID. This marries pallet with store and hence prevents putting other stores boxes on that pallet. Once the pallet is full or all the boxes are scanned the pallet is ready for move. Todays Delivery? If yes, then packer moves it to the shipping lane & scans pallet id & shipping lane. If No. then packer checks the volume of pallet , o If pallet is full then packer moves the pallet to pack & hold location & confirms the move by scanning pallet id & location id o If pallet is not full then packer moves it to put to store location & confirms the move by scanning the box id & location id. The move can box wise or pallet wise.

Exception Handling:

Picker does not find SKU in system suggested location Picker skips the task and specified reason code System suggest new task for picking. Picker then pick from new location and continue. This skipped task is then lost. In order to complete the skipped task, the allocation has to be done manually and picking through RF assisted option. Picker finds qty. mismatch at picking location. Picker updates the qty. picked & selects the correct reason code.

Business Rules:

WMS to calculate the Store Priority based on Store Matrix for Cluster Picking. Picker to have option to override the displayed consignee. Picking to be done always in the order line UOM. Incase of actual picked qty is less then suggested qty, WMS to spilt the task and show the new task created with pending qty. Reason code to be selected while short pick

WMS to trigger cycle count for a specific reason selected during SKU not available & qty mismatch. Short pick qty will be unallocated from the order line. Every Zone to have a Default Packing Consolidation Location WMS to print a Packing List (optional) and Shipping Label for each Box packed While consolidation at packing area One Store = One Pallet

Batch picking
Process Description:

Batch picking process enables warehouse to pick the fast moving SKUs in a batches.
Process Steps:

Picker logs into RF & selects batch picking option , area & sequence of picking. Picker logs into RF & selects batch picking option , area & sequence of picking. Picker confirms by scanning the location, SKU & updates the quantity Picker puts the qty. into pallet confirms by scanning the pallet id Pick completed? If yes then , Picker moves the pallet to staging area of put to store If no then picker continues task given by WMS.

Batch Picking
Picking and Put to store

Wave creation

Start

User Logs on to Batch picking option on RF and Selects Area, Sequence

WMS Suggests 1st Location, SKU & Qty to be Picked

Picker Confirms by Scanning the Location, SKU and Updates Qty Picked

Picker puts the Qty into the Pallet and Confirms by Scanning the Pallet ID

No

Pick complete Yes Picker Move Pallet to Inward Staging area of Put To Store

Put to Store
Put To Store Sorting user Scans the Pallet

WMS suggests Store Location ID and Qty for that store

PTS User make sure pre-labeled box(s) are available on un-packed pallet at store location Put To Store User Confirms by Scanning the Location, Updates Qty for one box

1a

1b

Put To Store User scans box id and Confirm

Yes

Store Pallet full

No

Helper moves the Pallet to packing Location and Brings new pallet at PTS location

WMS suggests New Task for SKU (new box for same store or new store) * Repeat steps 1a & 1b

All Task Completed for SKU


Yes

No

Any Pending SKU


No

Yes

Process Ends

Packing for Batch picking


Packing and movement of pallet to designated shipping lane/ Pack and hold location

Put to store

Starts

Brings unpacked boxes from put to store location to packing area

Helper

Logs on to RF and Selects Packing Option

Packer

Scans the BOX ID & Inputs the Weight (optional)

Packer

WMS Prints Shipping Label & Packing List, Paste the label

Prevents mixing of consignee on pallet

Puts the BOX on Pallet Scan the Shipping label, & Pallet ID

Packer

Packer Moves the pallet to Pack & Hold Location

No

Todays delivery?

Yes

Packers Scan the Pack & Hold Location ID and Confirms the Move

Moves to designated Shipping Lane

End