R.Ramachandran: Head-National Hubs
R.Ramachandran: Head-National Hubs
R.Ramachandran: Head-National Hubs
Limited,
Chennai
R.Ramachandran
Head-National Hubs
Part 1- Basics of Logistics
What is Logistics?
Logistics is that part of the supply chain
requirements.
Business Excellence - Need of the hour
Globalisation
Waste elimination
Concentrated on Logistics
• Quality
• Cost
Basics of Logistics Operation
MRP
Margin Observations
Logistics
Cost
Sales & • Logistics is a necessary cost
Administration
• It is a non-value added cost
Market Principle
Selling Price - Cost** = Profit
** To make a profit you have to keep costs below the price
you can sell
EFFICIENCY
APPARENT REAL
-2%
10%
-.5%
Reduction
1%
10% In
Cut Operating 3%
Off Expenses
The -.5%
Top
-2%
BUDGET
-1%
Work Processes
5 Key Concepts from LEAN
Delivery of Value to the Customer
Elimination of Waste
Problem Solving
QUANTITY
QUANTITY
- at the
COST
TIME
PLANNED BY AN
ORGANIZATION
How to Assure Deliver y
as much as possible,
as continuously as possible and
with as much first time quality as
possible
Man Work Product/
Machine Method
Service
Material
Waiting
Rework
Inventory
Conveyance
Over-Processing
Over-Production
Why Shorten Lead Time
It reduces unnecessary use of resources
on processing time
It forces attention to quality issues, their causes and their
cost.
It forces problems in the flow of the value stream as a
AP Strategies
Executive CD Business Objectives
AP AP Financial Performance
CD CD
Goals
Manager AP AP AP AP Ops/Project Plants
CD CD CD CD Budgets
Action Plans
Supervisor AP AP AP AP AP Production Schedules
AP
Team Leader CD CD CD CD CD Targets
CD
Staff
AP AP AP AP AP AP AP Assignments
Team CD CD CD CD CD CD CD Rates/Due Dates
AP AP AP AP AP AP AP AP Standards
CD CD CD CD CD CD CD CD
Out side
Container Yard
Imported
Parts
Local
Suppliers
Local Vendor
Vehicle
Receipt
Area
Changin
Oil
loading g from
spray
Pallet to
Bin
20 mts 15 mts 30 mts
2 hours 3 hours
Activity time 41 minutes
Represented by:
4Description of Land
5Original Owners
6 Description of Building
a)Age of the building No. of Years:
b)Building dimensions Area Length Width Height
i) Total Area
ii) Warehouse area
iii) Office area
iv) Open area
7Type of roof
Load
bearing
8Type of Flooring capacity:
9Warehouse Layout Enclosed
10 Specific details
a) Power:(KVA)
i) Capacity
ii) No. of phases
Sl. No Documents / Details to be checked Copy obtained Deed dated Enclosure Remarks
2 Previous tenent
3Telephone Yes / No
5Motor Yes / No
6Toilets Yes / No
9Painting Yes / No
11
12
13
14
15
S No D.Financial Deals / Negotiations
Done by /
1Rentals Proposed by the owner Date Rate / sq. ft Remarks
a)Warehouse Area
b)Office Area
c)Open Area
d)Amenities
e)Fixed Rentals
f)Total
No of
f)Advance / security deposit months Amount Remarks
Particulars
2 Final Negotiation
Done by /
a)Warehouse Area Remarks
b)Office Area
c)Open Area
d)Amenities
e)Fixed Rentals
f)Total
3Contract period
4Seperation clause
5Date of possession
Agreement Processing
Types of Warehouses
In plant Warehouse
Vehicle Stockyard
Loading at customer
MR Collection ---> premises,decanting at
SCM 1 A Consolidation at Origin
Hub ---> Line Haul --->
Delivery Hub,unloading at
customer premises,delivery
a a a a a
Destination hub ---> to line,collection of
Redlivery returnables
Loading at customer
MR Collection ---> premises,unloading at
SCM 2 B Consolidation at Origin
Hub ---> Line Haul --->
customer premises,line
side feeding,collection of
a a a a
Direct Delivery returnables.
C
B Storage Rack
C Stacker Crane
E Conveyor System
A J
F Sorter
F G DPS
I
H APS
H I Gantry
G
J Robot Palletizer
Logistic & Warehouse
Advantages
Stability of load handing through smooth acceleration &
deceleration controls by S-Curve
Increased load weight by super high-speed type
Stabilized structure design featured by low noise & low vibration
Easy maintenance through checking error code history &
Trouble shooting by monitor
Precision controlling driving & lift location through distance
measurement by Laser sensor and flexible correspond to lean of
rack
Slim Fork development in European Load area
(Thickness 65mm) – Minimalization of Fork Thickness
Products : SORTER
This system sorts individual materials to a
Advantages:
by requirements
Advantages :
High productivity at peak times
Reduction of time consumption for picking relying on
manual bills
Less personnel for picking thanks to location
management
and minimized working route
Efficient use of space thanks to high product density
Products : APS
(Automatic Picking system)
Advantages :
High productivity at peak times
High profitability thanks to elimination of time consuming
manual picking
Constant high quality and reliability even during peak times
Efficient use of space thanks to high product density
Products : GANTRY
Gantry is to provide greater volume coverage,
Advantages:
Adaptation to different crate and case sizes and types
Error-free picking
Stock in order and Flexible operations
Easy maneuvering
Low system noise level
Easy cleaning of the equipment and floor
ROBOT PALLETIZER
Robotic palletizing systems allow for more flexibility
Advantages :
Can be Operated within a small area
Multiple end effector applications for bags, boxes,
cases, etc.
Innovative, user-friendly Control
Saves time and increases reliability
Automatic diagnostics instantly identify errors
Increases uptime & operating efficiency
Flexible layout capabilities
Car Engine (Warehousing)
Beer (Warehousing)
(note)
TD : stands for Traslo Device.
Traslo is Italian which means 'transfer‘
Cage with trolley
Part 4 - Matrices
Data Updation Systems
THE VARIOUS SYSTEMS PRESENTLY USED ARE:
SAP
ERP
WMS
RFID
Perpetual Inventory
Bin Audit
Dock Audit
INVENTORY
Reduces Inventory 4
MinIN
3.5
Re-order Level
Simplifies Operations 2.5 trigger to Safety Stock
production
2
Allows Visibility into the schedule
Schedule changes
SUPPLIERS RECEIVING STORES
Card
Card Card Card Card
Card Card
Transport
CardCard
Card
Transport
CARD DROP
BOX & TRIGGER
Welding assy cell
ASSEMBLY
Fix “KANBAN CARD” On Carton Box
D1 Team
Small group
Product/process knowledge
Team leader
Team synergy
Remove ICA
Implement decision made at D5
Cross functional participation
Update all the documents, procedures etc
Train the workforce
Seek feedback from the customer
Objectives
D7 Prevent recurrence
Modify necessary systems (Practices/Procedures) to prevent
recurrence of
this problem or a similar problem
The goal is to change the system that allowed the problem to
occur in the first place
Enables lessons learned can be shared
Conserves resources by saving rework on other problems
D8 Recognize Team
Complete the team experience
Sincerely recognize both team and individual contributions
Encourage a repeat of the behavior
G8D Report-Illustration
Title Date Opened Last Updated
Multi model part shipment. 12-10-2001 15-10-2001
Product/Process Information Organization Information
Receiving Process TVSLL-KDPP
Dø Symptom(s) Multi model part was shipped as Sea
Dø Emergency Response Action(s) % Effective Date Implemented
1. Intimated SCM 100% 12-10-2001
2. Reversal of SEA shipment.
D1 Team (Name, Profs, Dept., Phone) D2 Problem Description
Champion: Prasad, M P&L Multi-model part no XS61-18K579-DC 180 nos shipped in Sea
Team Leader: Arunachalam container instead of multi-model shipment
Team Members:
Sampath - MP&L analyst
Hemanth - Receiving Analyst
Parthasarathy - Receiving Checker
D3 Interim Containment Action(s) % Effective Date Implemented
Followed up with SCM and diverted material 100% 12-10-2001
from Main Plant.
D4 Root Cause(s) % Contribution
Lack of Process control measure affected receiving checker's ability to concentrate 100%
D5 Chosen Permanent Corrective Action(s) % Effective
1. Different receiving color tags for multi model shipment parts.
2. Receiving Flag will be raised in CMMS3 by MP&L analyst 100%
3. MP&L analyst will track the multi model parts
D6 Implemented Permanent Corrective Action(s) Date Implemented
1. Different receiving color tags for multi model shipment parts.
2. Receiving Flag will be raised in CMMS3 by MP&L analyst
3. MP&L analyst will track the multi model parts 15-10-2001
D7 Prevent Recurrence Date Implemented
1. Regular awareness training.
2. Multi model shipment information to consolidators. 15-10-2001
D7 Systemic Prevent recommendations Responsibility
Multi model shipment part labels to be color coded by supplier MH&PE
D8 Team and Individual Recognition Date Closed Reported By
Personally thanked all the team members 15-10-2001 A.Arunachalam
5S CONCEPT OF
HOUSE KEEPING
Work place becomes popular, clean & better organised
Shop floor and office operations become easier and safer
Results are visible to everyone - insiders and outsiders
Visible results enhance generations of more new ideas
People are automatically disciplined
People become proud of a clean and organised work place
Resultant good company image generates more business
etc.,
Happier employees with high morale
Empty
Dust Bins Hazardous/Non
Safety Corner Hazardous
Stacking
Wrong X Correct
Stacking
height