CHAPTER- 4

BROAD AREA OF STUDY

4.1 LOGISTICS AND SUPPLY CHAINMANAGEMENT:

These days, it has become a fixture of our working lives: the internet of things (IoT).

Logistics at Bosch is no exception. And that is not all. The goal is to monitor flows of goods

digitally, without any gaps, and to harness artificial intelligence (AI) to optimize processes –

all in a global network that includes customers, logistics service providers (LSPs), and

suppliers. Working with these partners, Bosch develops innovative logistics concepts to ensure

that supply chains are competitive, reliable, and stable. The overarching aim is to respond

optimally and rapidly to customers’ individual wishes and requests.

Logistics Connected Supply Chain Digitalization is an essential part of this, and the

logistics of tomorrow is unthinkable without data. As a leading IoT company, Bosch is thinking

in visionary terms as it looks to the future – just as the company founder would have wanted.

Bosch logistics associates already use innovative technologies like AI and sensors today,

integrating them into their own systems in some cases. They then gradually further develop

these systems. Through it all, the focus is on making sure the entire supply chain is digitalized,

from the customer to the supplier. Bosch also takes the same approach to managing production

and internal transportation at its plants.

Pro Con is a good example. Logistics planners are constantly faced with the question

of when which order should go into production. With Pro Con, a software program developed

specifically for this purpose, the Bosch teams have an automated tool that allows them to

manage, visualize, and optimize processes. In this way, they can visualize the current

production situation in real time on screens at the plant, for example.

In Track is another example. The integrated supply chain event platform supports logistics

processes and offers mobile data collection solutions. At the same time, it connects the

associates working on the projects, allowing for transparency across the entire supply chain.
4.2 WAREHOUSE MANAGEMENT DAILY MONITORING
4.3 Warehouse daily monitoring SQCD:
 SQDC board is a daily process management tool used to provide insights swiftly and

visually on how the process is operating based on the 4 vital criteria: Safety, Quality, Delivery

and Cost
 1. : S-Safety: by implementing effective safety measures, companies can protect their

employees and reduce the risk of accidents and injuries in the warehouse. This can

help improve productivity, efficiency, and compliance, benefiting the company's

bottom line.

➢ safety incidents

Slips, trips, and falls can often occur in a warehouse environment because of the

fast-moving nature of this type of work. Hazards such as discarded boxes, box ties, cables or

spilt substances can all cause injury.

➢ Safety Training

Warehouse Safety Training – generally includes forklift operator certification, hazardous

material handling and storage training, and proper ergonomics and hazard identification in

warehousing.
 ➢ waste management - plastic / wood/ factory waste / metal / copper

Under the lean manufacturing system, seven wastes are identified: overproduction,

inventory, motion, defects, over-processing, waiting, and transport.

2. Q-Quality: Quality is the ability of a product or service to meet and exceed customer

expectations. It is the result of the efficiency of the entire production process formed

of men, material, and machinery. Customer requirements determine the quality scop
 ➢ Blocked stock Monitoring

Blocked stock monitoring in a warehouse refers to the process of tracking

and managing inventory that is temporarily unavailable for use or sale. This can occur for

a variety of reasons, such as damaged goods, items awaiting inspection or repair, or

inventory that has been set aside for a specific customer or order.

➢ Q2 Monitoring – inbound

Monitoring inbound activities in Q2 (second quarter) can be crucial for businesses

to ensure that their supply chain processes are running smoothly and efficiently. Here are

some key areas to monitor:

1. Supplier Performance: Keep an eye on your suppliers' performance metrics such

as lead times, order fulfillment rates, and quality control measures. Analyze their

performance and adjust where necessary to ensure that your inventory levels are

optimal.
 2. Transit Times: Monitor the transit times of inbound shipments to ensure that they

are arriving on schedule. This can help you avoid delays in production and reduce

the risk of stockouts.

3. Quality Control: Inspect incoming goods to ensure that they meet your quality

standards. This can help prevent defective products from being shipped to

customers, which can damage your reputation and result in costly returns.

4. Inventory Accuracy: Verify that the inventory received matches the purchase order

and that there are no discrepancies in the quantities or quality of the goods. This

can help prevent stockouts and overstocks, which can be costly for the business.

5. Communication: Establish clear lines of communication with your suppliers to

ensure that they are aware of your requirements and can provide updates on

shipment status or any issues that arise.

➢ customer related complaints

Monitoring customer-related complaints is an important aspect of any

business, as it helps to identify issues that are impacting customer satisfaction and

loyalty. Here are some key steps to consider when monitoring customer complaints:

➢ Shelf- life expiry data

Regularly Check Inventory: Regularly check inventory to ensure that

items approaching their expiration date are identified and handled appropriately. This

can include moving them to the front of the shelf or setting them aside for immediate

use or disposal.
➢ WH internal complaint

working in a safe and healthy environment, and that issues are addressed

promptly to prevent further problems. Here are some key steps to consider when

monitoring internal complaints in a warehouse:

1. Establish a Complaint Procedure: Develop a clear and concise procedure for

employees to report any issues or complaints they have. This can include a

dedicated hotline, email address, or online form.

2. Assign Responsibility: Assign responsibility to a specific team or individual to

handle and investigate complaints. This can be a dedicated HR team or a

supervisor responsible for the area where the complaint occurred.

3. Document Complaints: Document all complaints received, including the nature

of the complaint, who reported it, and any actions taken to address it. This will

help to track trends and identify areas for improvement.

4. Investigate Complaints: Investigate each complaint thoroughly, including

conducting interviews with the employee who reported it and any witnesses, and
 reviewing any relevant documentation or CCTV footage.

5. Take Action: Take appropriate action to address the complaint and prevent it from

happening again in the future. This can include implementing new policies or

procedures, providing additional training, or disciplining employees if necessary.

Follow-Up: Follow-up with the employee who reported the complaint to ensure

that the issue has been resolved to their satisfaction and to prevent any further

problems.

➢ ASN pending

Monitoring ASN (Advance Shipping Notice) pending in a warehouse is crucial

to ensure that inventory and supply chain processes are running smoothly. Here are

some key steps to consider when monitoring ASN pending in a warehouse:

1. Establish a System: Develop a system for tracking ASN pending in the warehouse. This

can be done manually or through an automated inventory management system.

2. Set Expectations: Set clear expectations with suppliers for when ASNs should be
 submitted, and what information should be included.

3. Monitor ASN Receipt: Monitor the receipt of ASNs to ensure that they are received on

time and contain all required information.

4. Follow-Up with Suppliers: Follow-up with suppliers who have not submitted ASNs or

whose ASNs are incomplete or inaccurate.

5. Investigate Discrepancies: Investigate any discrepancies between the ASN and the

actual inventory received, and take appropriate action to resolve the issue.

6. Optimize Inventory Management: Use ASN data to optimize inventory management

processes, such as improving forecasting accuracy, reducing lead times, and

minimizing stockouts. monitoring ASN pending in a warehouse, businesses can ensure

that inventory is being managed efficiently and accurately, which can lead to cost

savings, improved customer satisfaction, and a more efficient supply chain.

➢ Shop floor internal compliant

Monitoring internal complaints on the shop floor in a warehouse is important

to ensure that employees are working in a safe and healthy environment, and that
 issues are addressed promptly to prevent further problems. Here are some key steps

to consider when monitoring internal complaints on the shop floor in a warehouse:

1. Establish a Complaint Procedure: Develop a clear and concise procedure for

employees to report any issues or complaints they have while working on the

shop floor. This can include a dedicated hotline, email address, or online form.

2. Assign Responsibility: Assign responsibility to a specific team or individual to

handle and investigate complaints. This can be a dedicated HR team or a

supervisor responsible for the area where the complaint occurred.

3. Document Complaints: Document all complaints received, including the nature

of the complaint, who reported it, and any actions taken to address it. This will

help to track trends and identify areas for improvement.

➢ WH LPC OPL

Warehouse LPC OPL (Local Process Control and Operating Procedures)

refers to the standard operating procedures and processes that are developed and

implemented in a warehouse to ensure consistent and efficient operations. Here are

some key steps to consider when developing and implementing Warehouse LPC

OPL.
 ➢ Customer returns

Monitoring customer returns in a warehouse is important to ensure that

returned products are processed efficiently and accurately, and to identify any trends or

issues that may impact customer satisfaction. Here are some key steps to consider when

monitoring customer returns in a warehouse:

1. Establish a Returns Procedure: Develop a clear and concise procedure for

handling customer returns, including how to receive and process returned

products.

2. Assign Responsibility: Assign responsibility to a specific team or individual to

handle and investigate customer returns. This can be a dedicated returns team or

a supervisor responsible for the area where returns are processed.

3. Document Returns: Document all returns received, including the reason for the

return, the product returned, and any actions taken to process the return.

4. Inspect Returned Products: Inspect all returned products to ensure they are in the
 proper condition and can be resold, or if they need to be disposed of.

5. Investigate Return Trends: Investigate any trends or patterns in returns, such as

products that are frequently returned or common reasons for returns, and take

appropriate actions to address the root cause of the problem.

3. C-Cost: The biggest costs in most businesses are the four basic types of manufacturing

costs:

1. Raw materials

2. Direct labour

3. Variable overhead – production costs that increase or decrease depending on

the quantity produced. For example, electricity is a variable overhead. If a

company increases production, it will also increase the usage of equipment,

which will result in a higher electricity bill.

4. Fixed overhead
➢ Inbound truck utilizations

Monitoring inbound truck utilization in a warehouse is important to ensure that trucks

are being used efficiently, that inventory is being received on time, and that warehouse

operations are running smoothly. Here are some key steps to consider when monitoring

inbound truck utilization in a warehouse:

1. Establish a Tracking System: Develop a system for tracking inbound truck arrivals

and departures, as well as the amount of inventory being received.

2. Set Performance Goals: Set performance goals for inbound truck utilization, such as

a target number of trucks received per day or a target percentage of truck capacity

used.

3. Monitor Performance: Monitor inbound truck utilization performance regularly and

track progress towards performance goals.

4. Analyze Data: Analyze data on inbound truck utilization, such as the number of

trucks received, the amount of inventory received, and the capacity utilization of
 each truck.

5. Identify Trends: Identify trends in inbound truck utilization, such as peak delivery

times, common delivery routes, and areas where capacity is being underutilized.

6. Optimize Truck Utilization: Use data analysis to optimize inbound truck utilization,

such as adjusting delivery schedules, consolidating shipments, or negotiating better

delivery rates.

➢ Outbound truck utilizations

Monitoring outbound truck utilization is important to ensure that the warehouse is using

transportation resources efficiently and effectively. Here are some key steps to consider

when monitoring outbound truck utilization:

1. Establish Metrics: Develop key performance indicators (KPIs) to measure outbound

truck utilization, such as number of shipments per truck, average weight per

shipment, and turnaround time.

2. Track Data: Track data on outbound shipments and transportation, such as shipment

size, weight, and destination, and the number of trucks used.

 3. Analyze Utilization: Analyze outbound truck utilization data to identify trends, such

as which shipping lanes are underutilized or overutilized.

4. Optimize Routing: Use utilization data to optimize routing and scheduling to

minimize empty trucks, reduce transportation costs, and improve delivery times.

➢ Premium shipments inbound

Monitoring premium shipments inbound in a warehouse is important to ensure that

high-priority and time-sensitive shipments are processed and delivered promptly and

accurately. Here are some key steps to consider when monitoring premium shipments

inbound in a warehouse:

1. Identify Premium Shipments: Identify shipments that require special handling due

to their priority status, such as express or overnight deliveries.

2. Establish a System: Develop a system for tracking premium shipments inbound,

including their expected delivery time and any special handling instructions.
 3. Assign Responsibility: Assign responsibility to a specific team or individual to

handle and monitor premium shipments inbound. This can be a dedicated team or a

supervisor responsible for the area where the shipment is processed.

4. Monitor Shipments: Monitor premium shipments inbound to ensure that they are

received on time and processed promptly.

5. Communicate with Carriers: Communicate with carriers and logistics providers to

ensure that they are aware of the priority status of the shipment and to obtain updates

on delivery status.

6. Resolve Issues: Address any issues that may arise during the processing or delivery

of premium shipments, such as delays or damages.

7. Provide Regular Updates: Provide regular updates to the recipient of the premium

shipment on its delivery status and any special handling instructions.

➢ Premium shipments outbound

Monitoring premium shipments outbound in a warehouse is important to ensure that

high-priority shipments are processed efficiently and accurately, and to meet customer
expectations for fast delivery. Here are some key steps to consider when monitoring

premium shipments outbound in a warehouse:

1. Define Premium Shipments: Define what constitutes a premium shipment, such as

expedited delivery, high-value products, or time-sensitive goods.

2. Establish a Premium Shipment Procedure: Develop a clear and concise procedure

for handling premium shipments, including how to prioritize them and the necessary

steps for processing them.

3. Assign Responsibility: Assign responsibility to a specific team or individual to

handle and investigate premium shipments. This can be a dedicated premium

shipments team or a supervisor responsible for the area where premium shipments

are processed.

4. Monitor Premium Shipments: Monitor the processing of premium shipments to

ensure they are being handled promptly and accurately, and that they are shipped on

time.

5. Document Premium Shipments: Document all premium shipments processed,

including the customer’s name, shipment details, and any issues encountered.

6. Investigate Premium Shipment Issues: Investigate any issues or delays encountered

during the processing of premium shipments, and take appropriate actions to address

the root cause of the problem.

7. Optimize Premium Shipments Process: Use premium shipment data to optimize the

premium shipment process, such as improving the shipment tracking system,

enhancing communication with customers, or modifying shipping schedules to

accommodate premium shipments.

➢ Packaging density

Monitoring packaging density in a warehouse is important to ensure that inventory is stored

efficiently, and that warehouse space is optimized. Here are some key steps to consider

when monitoring packaging density in a warehouse:

1. Develop a Standard: Develop a standard for the maximum acceptable packaging

density in the warehouse, which considers the nature of the products, their fragility,

and their storage requirements.

2. Train Employees: Train employees on how to properly store inventory to ensure

maximum packaging density is achieved.

3. Conduct Regular Audits: Conduct regular audits of the warehouse to ensure that

inventory is being stored at the appropriate packaging density.

4. Optimize Warehouse Layout: Optimize the warehouse layout to maximize storage

space, such as by using racks, shelves, or pallets.

5. Utilize Automation: Utilize automation tools, such as warehouse management

 systems (WMS), to track inventory and optimize warehouse space.

6. Monitor Inventory Turnover: Monitor inventory turnover to ensure that products are

moving quickly enough to make room for new inventory, and to identify products

that may need to be discounted or removed from the inventory.

➢ air and sea monitoring

Monitoring air and sea shipments in a warehouse is important to ensure that products

are received and shipped on time, and that any issues are addressed promptly to prevent

delays or disruptions in the supply chain. Here are some key steps to consider when

monitoring air and sea shipments in a warehouse:

1. Establish a Shipment Monitoring Procedure: Develop a clear and concise procedure

for monitoring air and sea shipments, including how to track shipments, how to

report any delays or issues, and how to follow up with suppliers or carriers.

2. Assign Responsibility: Assign responsibility to a specific team or individual to

monitor air and sea shipments. This can be a dedicated logistics team or a supervisor

responsible for the area where shipments are received and processed.

3. Track Shipments: Use a tracking system to monitor air and sea shipments and ensure
 they are received and shipped on time.

4. Communicate with Suppliers and Carriers: Communicate regularly with suppliers

and carriers to ensure that they are aware of any delays or issues, and to find solutions

to any problems that arise.

5. Investigate Shipment Delays: Investigate any delays in air and sea shipments, and

take appropriate action to address the root cause of the delay, such as expediting a

shipment or finding an alternate carrier.

6. Optimize Shipment Process: Use shipment data to optimize the shipment process,

such as improving forecasting accuracy, reducing lead times, and minimizing

transportation costs.

4. D-Delivery; Logistics are an essential part in providing good customer service on

time. Logistics customer service can be separated into three elements:

1 Pre-transaction elements (before delivery)

2 Transaction elements (during delivery)

3 Post-transaction elements (after delivery)

➢ GRN pending
 GRN (Goods Receipt Note) pending monitoring in a warehouse is crucial to ensure

that all inventory items are properly received and accounted

➢ GRN Productivity

Monitoring GRN (Goods Received Note) productivity in a warehouse is important

to ensure that the receiving process is efficient and accurate, and to identify any potential

bottlenecks or inefficiencies that may impact operations.

➢ Super Market Fulfillment

 Monitoring super market fulfillment in a warehouse is important to ensure

that the inventory is being managed efficiently and accurately, and that customer

orders are fulfilled in a timely and accurate manner. Here are some key steps to

consider when monitoring super market fulfillment in a warehouse:

1. Establish Inventory Management Procedures: Develop procedures for

receiving, storing, and managing inventory in the warehouse. This can include

using barcodes or RFID tags to track inventory, and implementing inventory

management software.

2. Monitor Inventory Levels: Monitor inventory levels to ensure that products are

in stock and available for fulfillment. Use inventory data to optimize the

replenishment process and prevent stockouts.

3. Track Order Fulfillment: Track order fulfillment from receipt to delivery. Use

order data to identify potential bottlenecks in the fulfillment process and to

improve accuracy and speed of order fulfillment.

4. Optimize Picking and Packing Processes: Optimize the picking and packing

processes to improve accuracy and speed of order fulfillment. This can include

implementing a pick-to-light system or using handheld scanners to improve

efficiency.

5. Monitor Shipping and Delivery: Monitor shipping and delivery to ensure that

orders are delivered on time and in the proper condition. Use delivery data to

identify potential issues and to improve the delivery process.

6. Analyze Metrics: Analyze metrics related to super market fulfillment, such as

order accuracy, order cycle time, and customer satisfaction, to identify areas for

improvement and to track progress over time.

➢ Super Market Productivity

Monitoring supermarket productivity in a warehouse involves tracking

key performance indicators (KPIs) that reflect the efficiency and effectiveness of

warehouse operations in supporting the needs of supermarkets. Here are some key

steps to consider when monitoring supermarket productivity in a warehouse:

1. Define KPIs: Define KPIs that reflect the needs of supermarkets, such as order

fulfillment rates, order accuracy, on-time delivery, and inventory accuracy.

2. Establish Targets: Establish targets for each KPI that reflect the expectations of

supermarkets, and track progress against those targets over time.

3. Track Performance: Regularly track performance against KPIs, and report the

results to key stakeholders such as supermarkets and warehouse management.

4. Identify Opportunities for Improvement: Use performance data to identify

opportunities for improvement, such as reducing order processing times,

improving inventory accuracy, or implementing automation to reduce labor costs.

 5. Implement Process Improvements: Implement process improvements to address

identified opportunities for improvement, and track the impact of those

improvements on performance against KPIs.

6. Continuously Monitor and Improve: Continuously monitor and improve

supermarket productivity in the warehouse by regularly reviewing KPIs,

identifying new opportunities for improvement, and implementing process

improvements.

➢ Production Line stoppage

Monitoring production line stoppages in a warehouse can be crucial for

maintaining efficiency and minimizing downtime. Here are some potential steps that

could be taken to monitor and address production line stoppages:

1. Install sensors: One way to monitor production line stoppages is by installing

sensors on the equipment. These sensors can detect when a machine has stopped

or when there is a malfunction, and send an alert to the relevant personnel.

 2. Set up a monitoring system: Another option is to set up a monitoring system that

tracks the equipment in real-time. This could be done using software that tracks

the performance of each machine and alerts staff when there are any issues.

3. Train staff: It is important to train staff on how to identify and address production

line stoppages. This could include training on how to use equipment properly,

how to detect issues early on, and how to troubleshoot common problems.

4. Establish maintenance protocols: Implementing regular maintenance protocols

can help prevent production line stoppages caused by equipment failure. This

could involve scheduling regular maintenance checks or servicing the equipment

after a certain number of hours of operation.

5. Conduct regular reviews: It is important to conduct regular reviews of production

line stoppages to identify trends and areas for improvement. This could involve

analyzing data on stoppages, identifying common causes, and implementing

solutions to address those issues.

➢ TO confirmation with in 1hrs

 TO (Transfer Order) confirmation monitoring is an important process in warehouse

management. It involves verifying that the transfer orders created in the system have been

physically executed in the warehouse as intended.

Here are some steps that can be followed for TO confirmation monitoring:

1. Verify the transfer order: Check the details of the transfer order in the system, including

the source location, destination location, quantity, and any special instructions or notes.

2. Physical verification: Confirm that the physical movement of goods has occurred as per

the transfer order. Check that the goods have been moved from the source location to

the destination location and that the quantity matches the transfer order.

3. Documentation: Ensure that all necessary documentation related to the transfer order,

such as receipts or packing slips, have been generated and recorded accurately.

4. Inspection: Conduct a quality inspection of the goods to ensure that they are in good

condition and meet the required standards.

5. Record keeping: Record the results of the confirmation monitoring process in the

system for future reference.

UPDATE DATA SHEET;

4.4 STOCK ACCURACY & LOCATION ACCURACY MONITORING:

❖ STOCK ACCURACY MONITORING

Inventory accuracy is a metric that measures the difference between your records of

warehouse stock and your real-life inventory. Inventory accuracy is critical for preventing

stockouts, shortages, shrinkage, controlling inventory quality, and maintaining a positive

customer experience

Daily stock accuracy checking in SAP and physical

 ❖ LOCATION ACCURACY MONITORING

A system for managing the physical location of inventory within a warehouse or stock

compound. Stock items are segregated by issue frequency, size, issue quantity, attractiveness

or type and placed in dedicated locations within a warehouse or compound.

Daily location accuracy checking in SAP and physical