GATI SHAKTI VISHWAVIDYALAYA

(A Central University under Ministry of Railways, Government of India)

NAIR Campus, Lalbaug Vadodara, Gujarat-390004

Warehouse Management
Group Assignment

Group No. — 05

Group Members Details

Name Roll. No
Ashutosh Kumar Singh 201014
Ayan Kumar 201017
Jayant Shekhar 201031
Jyoti Prakash Mishra 201032
Shubham Kumar 201058
Sk Fayez Ali 201059
A Brief Introduction
The warehouse mainly consists of office products. The total SKUs in the warehouse are
18,866 and the total number of SKUs shipped by the warehouse are 1,88,604. There are a
total of 8 zones in the warehouse, namely, A, B, C, D, E, G, H and P. The number of bays are
44 and the number of aisles are 47. The record of date of first transaction (DOFT) happened
in the period between 02-04-1995 to 24-02-1997. The order shipment date ranges from 06-
01-1997 to 31-01-1997. For analysis of the case study, MS Excel and Power BI are used.

1) Describe the skus. For example: Where are they? Which are most popular? On what
percentage of orders do they appear? How many skus are never requested? How does
the population of skus change over time?

Ans.- SKUs are unique codes given to a product and consist of a unique letter and number
which characterises its brand, quality, quantity etc. and is used to identify and track its
inventory. They are normally found on product bodies with a unique code. Here, in this case
study, the SKUs are office products supplied by 314 vendors. The SKUs are stored in 8 zones
consisting of 44 bays and 47 aisles.

Fig 1. 1
From the above pie-chart Fig 1.1, it can be stated that most of the SKUs, that is, about
61.95% of the SKUs are on a mezzanine, that is, zones A and B. About 19.95% of the SKUs,
that is, 37,64,000 SKUs are downstairs in Zone C and D; followed by 7.51% in Zone G and
2.6% in Zone E.

Fig 1.2

According to fig. 1.2, the most popular SKU is SPR06120 ordered a total of 32,944 times.
The second most popular SKU is PAP303-01 ordered a total of 12511 times followed by
SPRW2011 at 9331 times and SAN3OO01 at 8932 times. The top 5 SKUs constitute a total
of 72,570 ordered items.
 Fig 1.3

As stated before, the most popular SKU with the SKU Id, SPR06120 has the highest
percentage of orders, that is, 2.66%. This is followed by 1.01% of SKU with SKU id,
PAP303-01 and 0.75% of orders placed on SPRW2011.

There are a total 18866 SKUs present in the warehouse. The total number of SKUs that are
ordered are 16609. The number of SKUs that are not ordered are 2,257 (18866 -16609).

Fig. 1.4
The maximum number of items are ordered on 02-04-1995 followed by 30-04-1995 and 30-
07-1995. The number of ordered items is gradually decreasing over time.

2) Describe the work. How much is there and where is it? For example, how is it
distributed among skus, among zones, among aisles, among bays, among orders, among
vendors, among days, etc.?

Ans:- The warehouse activities consist of storing the SKUs and then shipping them as per the
received orders. There are a total of 18,866 types of SKUs present in the warehouse and they
are stored in different zones as per their dimensions and prescribed storage instructions.
There are a total of 56,743 orders placed in the warehouse. The work i.e., storage and
shipment of items is distributed as follows:

Fig. 2.1
For the finest level of packaging that the warehouse might handle, 85.32% of the total SKUs
are stored in EA (each) form followed by ST (set) form.
 Fig. 2.2
For coarser levels of packaging, the maximum number of items are stored in BX (box) form
constituting about 38.35% of the total SKUs.

Fig. 2.3
For an even more coarser level of packaging, the maximum number of SKUs are not defined
in any particular way of packaging.

Fig. 2.4
For shipment of items, the SKU shipped highest is SPR06120 which stands at 4.53% of the
total shipped items.
 Fig. 2.5
Order Id 21974 contributes about 1.08% of the total items shipped which is the highest
among all orders.

Fig. 2.6
The highest number of order shipments was carried out on 21-01-1997 which contributes
about 7.9% of the total shipments.
 Fig. 2.7
The bay contributing to the highest number of shipments is Bay 33. It is contributing to
5.34% of the total shipments.

Fig. 2.8
Aisle 4 is contributing to the highest number of shipments and stands at 9.15% of the total
orders shipped.

Fig. 2.9
The vendor whose shipped items constitute the largest part of the total shipment is ACC,
standing at 8.67% of the total shipments.

3) Describe the orders. For example: What percentage of orders are for a single line?
What percentage is for more than 20 lines? What is the distribution of lines per order?
What is the distribution of lines per order within each zone? What percentage of the
labour do single-line orders represent? Orders with more than 20 lines? What
percentage of orders touch the mezzanine (zones A, B)? Bin-shelving on the floor (zones
C, D)? The security zone (E)? Pallet rack (G)? What percentage of orders are
completed entirely on the mezzanine (that is, within zones A and B)? Entirely within
floor shelving (that is, within zones C and D)? Entirely within the high security area, for
valuable items (zone E)? Entirely within the pallet rack (zone G)? How many orders are
completed with each of the possible pairs of zones?
 Fig. 3.1

Single line orders are 34,276 and constitute about 60.41% of the total orders. The number of
orders having more than 20 lines are 1405 constituting about 2.48% of the total orders.

Fig. 3.2
The order id 22767 has a maximum number of 189 lines followed by order id 40455 having
182 lines.
 Fig. 3.3
A zone has the maximum number of orders contributing to 27.22% of the total orders.

Fig. 3.4
The order id 22767 has a maximum number of 189 lines in which 65 orders are from zone A,
63 items are from zone B, 24 items are from zone C followed by zone D, G and H having 7, 7
and 0 items respectively.

Fig. 3.5
The number of orders touching the mezzanine (zones A, B) is 24,821 + 22,923 = 47,744. This
constitutes 84.14% of the total orders.

Fig. 3.6
The number of orders touching the Bin-shelving on the floor (zones C, D) is 10,769 + 10,075
= 20,844. This constitutes 36.73% of the total orders.

Fig. 3.7
The number of orders touching the security zone (E) is 3,824. This constitutes 6.74% of the
total orders.

Fig. 3.8
The number of orders that are picked from security area (zone E) is 8,820. This constitutes
15.54% of the total orders.

Fig 3.9

The highest number of orders entirely completed within a zone are on the Mezzanine zone
(Zones A & B), that is, about 68.08% of the total orders. This is followed by the 18.65% on
the Shelving zones (Zones C & D) and 9.65%, 3.62% in the Pallet Rack (zone G) and
Security Area (zone E) respectively.

4) Where are the shipping discrepancies (quantity shipped < quantity ordered)? In what
skus, zones, days, etc?
 Fig. 4.1
The total number of SKUs ordered are 12,38,566 and out of those only 11,54,519 SKUs are
shipped which is 93.21% of the total items ordered.

Fig. 4.2
For discrepancies based on SKUs, the highest difference between items ordered and shipped
is for SKU id PAP303-01 which is of 2937 items. For this item, the ordered quantity was
12,511 and only 9574 were shipped to the customers.
 Fig. 4.3
For discrepancies based on zone, the highest discrepancies are found for zone B followed by
zone A. At B, 4,39,433 items were ordered and out of those only 4,11,082 were shipped. The
difference between items ordered and shipped stands at 28,351 at zone B which is way
higher than any other zone.

Fig. 4.4
For discrepancies based on date of order, the highest discrepancies was found for 14-01-1997
on which the numbers of orders were 63,773 and out of those only 56,861 items were shipped
bringing the difference in ordered and shipped quantities to 6,912 which is higher than any
other date. The next highest order discrepancies was found on 21-01-1997 having a
difference in orders and shipment of 6,846 items.
Fig 4.5
For discrepancies based on bay, the highest discrepancies are found for items which haven’t
been assigned to any bay followed by bay 25. The items that weren’t stored in any bay were

ordered 38,760 times and out of those only 26,721 were shipped. The difference between
items ordered and shipped stands at 12,039 which is way higher than any items stored at
bays.

Fig. 4.6
For discrepancies based on aisle, the highest discrepancies are found for items which haven’t
been assigned to any aisle followed by aisle 15. The items that weren’t stored in any aisle
were ordered 38,760 times and out of those only 26,721 were shipped. The difference
between items ordered and shipped stands at 12,039 which is way higher than any items
stored at any aisle.

Conclusion
Based on the data studied, the zones carrying out the majority of the operations are Zone A
and B and out of these two the highest shipping discrepancies are found in Zone B.
Therefore, optimization of Zone B should take place followed by Zone A. For bays and
aisles, the maximum shipping discrepancies was found for items which weren’t assigned to
any bay or aisles, So, for maximising the shipping efficiency, all incoming items to the
warehouse must be assigned to a bay or aisle. The maximum shipping discrepancies was
experienced in the month of January, so the warehouse could hire additional staff for these
peak months to tackle the huge demand. The item which experienced the maximum
discrepancies was having an SKU id PAP3O3-01. This was also the 2nd most ordered item
from the warehouse. So, this item could be given higher priority in storage to optimise the
overall efficiency of the warehouse.