Warehouse Operations

Activities in a warehouse

Warehouse Operations

Purpose of a warehouse

Warehouse can be a strategic tool for:

Inventory Management

Customer Service

Compliance, document management

and information requested

Warehouse Operations

Strategic intent of a warehouse

Warehouse Operations

Activities in a warehouse

Receive Goods

Identify Goods

Put Way

Picking Goods

Hold Goods

Packing and shipment

Sorting / Consolidation

Marshal The Shipment

Replacement

Pre packing

Customer Service

Manage information systems

and reporting

Warehouse Operations

Material Receipt Process

Received in a designated area (Marshalling area) Initial check for quantity

and physical damage identification and tagging of materials pre packing

Physical ReceiptInspection for basic

specifications

Testing / inspection for technical specifications

Document Inspection Records

Accept / Reject

Warehouse Operations

Material Receipt Process

Goods are inspected for quality and quantity

Conformance to specifications as per order

Inspected damage goods

Inspected Delivery date

Outcome for inspection is:

Acceptance / Rejection

Generate Good Received Note ( GNR)

Warehouse Operations

Key objectives of inspection

To sort out poor quality of materials and manufactured goods

To establish and increase the reputation by protecting

customers from receiving poor quality products

Direct source of errors and failure in the finished products and

contribute to better design and production process

To distinguish good pieces from bad pieces

To determine if the process it conforming to standards and consistently

delivering efficiency

To determine if the process is adequate in view of changing standards of

product quality and demand

To rate quality of products

To rate Accuracy of inspectors:

To measure the precision of the measuring instrument

To measure process capability

Warehouse Operations

Purpose of the inspection process

Warehouse operation

Material Receipt Process

The purpose of this documentation is multifold

Evidence of having received materials

Evidence of having conducted inspection

Log of all testing done with results

Log of all rejected item records

Audit trail of inspection & inspectors involved in the

process

Traceability of parts when they fail in the field

Data analysis of parts, product & supplier

RECEIPT DOCUMENTATION

Warehouse operation

Material Receipt Process

THIS IS A VERY IMPORTANT DOCUMENT THAT RECORDS:

QUANTITY ORDERED

QUANTITY DELIVERED

QUANTITY ACCEPTED

Warehouse operation

Material Receipt Process

KEY ELEMENTS OF AN ID INCLUDE:

Identification Tags For The Goods

Warehouse operation

Material Receipt Process

Before put away, the goods are:

STORED

LABELLED

LOCATION IS IDENTIFIED

Warehouse operation

Material Receipt Process

STORAGE IS MEANT TO PROTECT GOODS FROM:

Pilferage

Fire Hazards

Damage

Atmospheric conditions

Temperature, Pressure

Temperature, Pressure

Humidity, Rain, Dust

Warehouse Operations

Picking

The picking process includes:

Identifying the goods to be picked

Automation solutions like Bar-coding, RAFID would help

Automation solutions like Bar-coding, RAFID would help

Safe removal without affecting other goods. This would be

possible if:

Goods are accessible

Location records are updated

Warehouse Operations

Picking

DISPATCH

The dispatch process includes:

Delivery order

Protective packaging

Loading and securing

Pick List

Documentation

System Transaction Update

Warehouse Operations

Picking

Physical Verification

Inaccurate Inventory Data Could Result In:

Lost Sales

Disrupted schedules

Poor Delivery Performance

Excess Inventory Of The Wrong Things

Low Productivity

Excess Expediting

Warehouse Operations

Physical verification process

Count the items and record the count on tickets left with the item

Verify the count, Sampling may be used

Collect the tickets and list all items

Collect the tickets and list all items

Reconcile the inventory

Investigate reason for discrepancies

Reconcile the inventory

Correct inventory balance

Update financial records

Warehouse Operations

Physical verification process

Timely correction of errors

Reduction of lost production

Use of trained personnel

Familiar with the items

Fewer errors

Fewer errors

Warehouse Operations

Physical verification process

Information Systems

A warehouse should keep accurate records of all transactions for:-

Audit

Traceability

Quick response to delivery requirements

Compliance Performance management

Process documentation

Warehouse Operations

Physical verification process

Receipt

Identification

Put away

Picking

Packing

Shipment

Information Management

Physical Verification