Case Studies

Client

ITO EN, United States of America

Project Outline

  •  “AS IS” Process study & Mapping for a
  • Coffee Manufacturing & Distribution
  • Herbal and Vitamin Manufacturing & Distribution
  • Juice Manufacturing & Distribution

Functional Areas Covered

  • Demand Forecasting
  • Production Planning – including Automatic Trigger from Inventory Management
  • Purchase Management – including Automatic Trigger from Inventory Management
  • Warehouse Management – including Automatic Put Away, Picking, Replenishments
  • Sales Order Management
  • Delivery Management
  • Quality Management

Benefits to Customer

ü Smooth Work Flow – No reminders / Follow up

Paper “Less” to Paperless Office.

Client

  • Reliance Retail (Chennai, Madurai & Coimbatore DCs) – SAP WMS
  • Saint Gobain Glass (Chennai Plant – Mother WH, Delhi – Feeder WH) – SAP SD & Logistics of Glass (LG)

Project Outline

  • Warehouse Capacity Workings – Receiving, Put Away, Storage, Picking & Delivery
  •  Warehouse Layout & Facilities Planning
  • Area Calculations
  • No of Racks / Bins Required – Mezzanine & Non Mezzanine
  • Facilities & Utilities Planning
  • MHE requirements
  • Manpower Planning

Warehouse Management Systems (WMS) – Design, Implementation & Training

  • Receipt, Put Away, Inventory Management, Picking, Staging and Delivery
  • The TO BE Process includes Automatic Put Away, Picking & Replenishment strategies.

Benefits to Customer

  • Error Proof Layout – Single Flow concept, No scope for mixing – leading to High Inventory Accuracy Levels
  •  High Productivity levels – Avg 900 lines per Picker achieved. Highest across 23 DCs in India.

Client

  • Saravana Stores, Chennai – SAP Business One

Before

  • 3 Hyper Stores operating in Chennai.
  • Mostly manual Process except payment Processing to Vendors.
  • High level of Stock inaccuracies. For instance
  • Few lakhs of Stock Write Off only for Kareel Leaves over 6 months.

 Duration : 1 Month

After

  • Process Blue Print developed for SAP WMS (Wet) operations
  • Complete integration of Data between SAP – WMS to Billing System leading to Zero Inventory loss.
  • Same Manpower for 5 Hyper Operations – No Increase in Manpower. Job Enhancement projected.

Benefits to Customer

Error Proof Operations – Frequent Write Offs eliminated.

  •  Highly Visible Inventory at every stage – Sales Counters, Back End Stores, In Receipt etc.
  • Faster Replenishment to Sales Counters – less Opportunity loss.

Client

  • Autoprint, Coimbatore – Inhouse Developed s/w
  • OPG PowerGen Pvt Ltd, Chennai – SAP R3

Before

 Autoprint, CBEOPG Power Gen, Chennai
  • Delay in Machine Building – Delay in Delivery. Hence, dissatisfied Customers
  • Primarily due to Non-availability of Critical parts
  • Average No of Purchase Requests per month – 300 to 400. 
  • Ad-hoc Purchase – As & when and in Small quantities

What was done

  • ABC – XYZ analysis done on Components / Parts / Consumables.
  • Criticality to Machine Building arrived. Highly Critical, Can be managed, Not Critical
  • Inventory Norms (Min / Max Stock, ROL, ROQ) arrived at based on lead times of Procurement.

Benefits to Customer

 Autoprint, CBEOPG Power Gen, Chennai
  • Predictability improved on Delivery Commitments made to Customers.
  • Less Queuing effect. Better planning made possible.
  • Lean Inventory. No unnecessary parts in Engg Stores.
  • Average PRs reduced from 300 per month to 30. Most of the Regular parts & Consumables brought under Auto triggering based on ROL.
  • Manpower in Purchase Department from 10 to 3.

Client

  • Giri Trading Company, Chennai – SAP Business One

Before

  • 22 Stores in Tamil Nadu, Karnataka, Delhi & Maharashtra.
  • Central Warehouse in Chennai.
  • High level of Stock inaccuracies.
  • Delayed Services to Stores.
Inventory maintained is slightly more than actual Sales Turn Over. (Inventory evaluated @ Sales price) leading to Cash crunch.

After

  • Process Blue Print developed for SAP WMS (Retail) operations
  • ABC Analysis done and Re-Order Level (RoL) fixing for Top Moving Items.
  • “Flow Thru Concept” – for Slow Moving items. No Storage in Warehouse.
  • Warehouse Space Management Improved and Inventory levels brought down improving Cash flow.

Benefits to Customer

  • Error Proof Operations – Warehouse Stock Accuracy Improved leading to faster Deliveries.
  • Cash Flow Improved
 

Client

  • Autoprint, Coimbatore
  • OPG PowerGen, Chennai
  • Chettinadu Cements, Chennai

Before

  • No Clear Job Descriptions for each Role level of Stock inaccuracies.
  • No Objective Goal Setting & Measurement
  • Salary Increments – NOT linked to Performance
 

After

  • Goals Developed based on Balance Score Card for each role.
  • Job Descriptions, KRA, KPI defined for each role.
  • Performance based Goal Evaluation and Appraisals
  • HR – Systems & SOPs Manual

Benefits to Customer

  • Personal Bias Removed in appraisals.
  • Better Role Clarity