WAREHOUSE VISIT

Dated: - 27th August 2013

We visited two warehouses located in Bhiwandi.

1. Agility 2. Future Supply Chain

AGILITY

A Kuwait based company having a warehouse facility in

India in Bhiwandi.

It is a 27 lakh sq. ft. area spread warehouse facility

It serves 7 major customers under this single shed

Among them BMW is the priority based customer and has

30 facilities for the same PAN India.

Office area

Fig: Layout

Racks

Entrances and exits

For loading unloading

Customs bonded area

Mezzanine area for BMW

Air conditioned area

Inbound staging area

Outbound staging area

1. There are inbound staging area and outbound staging

area where sticking and labelling is done for the

customers as per their requirement.

2. It is done on the basis of VOR that is for very urgent orders

and stock to order for regular orders.

3. As seen for BMW the area it is designed as per the norms

set by the BMW Company.

4. It stocks 12000 SKU’s

5. As for inventory 1 picker and 1 checker is assigned for the

same.

6. The productivity is as – 18 to 20 lines / hour

7. Inventory is checked periodically.

8. Everything is manually done here.

9. There is also an area for waste and damaged products in

the warehouse.

10.

FUTURE SUPPLY CHAIN

At the K2-DC Distribution Centres/ Warehouses catering to Fashion brands is done,

A leading edge Warehouse Management System and Processes have been implemented which support the large SKU base of Fashion category and Fashion specific processes like single and mixed SKU cross dock, handling pre-packs, sale sets etc.The Put to Light Sortation System, the first of its kind in India, enables category specific and delivery point specific segregation. No further sortation is required at the receiving end.An auto Outbound Weigh Check System integrated with auto Print & Apply System ensures 100% dispatch accuracy.

They use ‘scientific supply chain management’ for the Fashion Supply Chain which includes: -

1. Multi- user, Shared- user or Dedicated state-of-the-art

automated Distribution Centres/ Warehousing having

2. Multi- level racking, shelving and Material Handling

equipment for safe and secure handling

3. Cross dock operations

4. Inbound & Outbound Automation, Conveyors and Sortation

Systems

5. Pan India Distribution and Last Mile Fulfilment Network

through Express and Customised Movement Solutions

Fig: Layout of the warehouse

Brands served here are:

1. PT fashion pantaloons

2. Lee Cooper

3. Brand factory

4. All

5. PFO fashion

Technology used:1. HHT (hand held terminals)

2. Wi-Fi over the warehouse area

3. Automated systems

4. Upgraded machines and forklifts

Fig: technology used

Working in the warehouse:1. Each employee is having a unique ID and password on

their own HHT device, which they operate for doing their particular task.

2. Tracking is done SKU wise 3. The reviewing step is as follows

a. Verify the productb. Inward of the productc. Location of the product

4. After tracking of the product , the next step is allotment, the place is already defined in the computer system and connected to the HHT

5. Various tags are used along with the codification

Eg: X is for whole box

B is for break pack

R is for storage residual

6. The category requirement is pre decided according to the requirement and availability of space.

7. The mezzanine area has Bin system to stock the clothes each have a location name

8. Every morning there is auto replenishment done.9. Thus the process is in the order receiving-allotment-put

away-order10. Picking is of two types batch(bulk to order) AND

cluster (multiple to store)