18 Questions
How can the POD team ensure zero IGCC (M+W) during order processing and fulfillment?
Mandate PICK & PACK for all pickers, ensure picking is done in bags/baskets only, eliminate barcode stickers on racks/walls, and have pickers inform the SM about any exceptions or EBMs.
What steps should be taken to improve inventory accuracy during the inwarding process?
Keep the inwarding and staging area clean, complete unloading within 30-45 minutes, track pendency in the app every 30 minutes, and double-check putaway before raising a PR.
How can the POD team maintain better inventory control during order fulfillment?
Mandate that pickers use bags/baskets for picking, eliminate the use of barcode stickers on racks/walls, and have pickers inform the SM about any exceptions or EBMs.
What strategies can be employed to boost people productivity and motivation within the POD?
Recognize top performers, provide higher incentives and recognition, increase team performance through better morale, and ensure SM RCA adherence by 4 PM daily.
During peak hours, what challenges might the POD face, and what solutions are proposed?
Challenges include inwarding delays due to missed GRN loaders, low inventory quality and accuracy. Solutions involve calling loaders before shift start, having SMs/pickers log in as loaders, and getting loaders from nearby PODs.
How can the POD team ensure timely and efficient order processing during peak hours?
Clear pendency from the manager app in real-time, hustle loaders to avoid idle time, and track pendency in the app every 30 minutes to minimize delays.
Explain the process for handling peak hour challenges in order processing and fulfillment.
Placement on Handler Pigeon Hole MFR masking Solutions Deploy handler for morning/evening peak Cross train pickers/loaders as handlers Real Time monitoring of DE queuing SM to login as Handler if queuing is >5 DEs Warning defaulters of MFR masking
What are the key goals and challenges related to inventory management accuracy? Propose solutions.
Goal: 100% items at CORRECT LOCATION with CORRECT QUANTITY. Challenges: SKU count & location inaccuracies, Cycle count task pendency, Process non-adherence of FEFO, sample audits. Solutions: Putaway at mapped locations only, Daily cycle count tasks completion, Daily sample audit by SM for 50 SKUs, 100% adherence of FEFO process, Allow picking from picking racks ONLY, Daily FnV batch correction before fresh stock arrival.
How can inventory losses due to damages, pilferages, and infrastructure issues be controlled? Provide a comprehensive solution.
Solutions: 100% adherence to Frisking Process, SG recording, 100% material movement, Timely stock adjustment post Cycle count, Accuracy Check of 50 SKUs daily, 360 degree positioning of CCTV Camera, Daily Gate Meeting with Loaders - Wastage Value, Regular Pest Control Treatments, Timely tickets for equipment issues, Minimum Batch Changes, Personal phones NOT allowed within PODs.
Calculate the target productivity levels mentioned in the text for pickers and loaders. Express your answer in the form: 'Pickers: X IPP, Loaders: Y IPL'
Pickers: 750 IPP, Loaders: 2000 IPL
What are the current challenges faced in achieving the desired people productivity and motivation levels? Propose solutions to overcome these challenges.
Current Challenges: Mandate marking attendance at start of shift, High UPL & Attrition, Low Productivity. Solutions: Daily Gate Meeting - NON NEGOTIABLE, Dashboard adoption to drive performance, Cross utilize pick
Summarize the key performance indicators (KPIs) and metrics mentioned in the text across different operational areas.
KPIs mentioned: 100% items at correct location with correct quantity (Inventory Accuracy), ZERO Damages & Pilferages (Inventory Control), 750 IPP, 2000 IPL (People Productivity), MFR masking, DE queuing >5 (Order Processing), Cycle count task pendency, FEFO adherence (Inventory Management processes).
What is the primary goal for Order Processing & Fulfillment related to IGCC (Inventory Accuracy)?
Ensuring Clean & Fresh products reach the customers.
What are the key challenges faced in maintaining IGCC and the corresponding solutions?
Challenges: Delay in removing malfunctioning/unsellable items, dirty/dusty SKUs, non-adherence to FEFO & stacking norms. Solutions: Remove unsellable SKUs by 2am daily, reject poor quality at inward, 100% FEFO adherence for F&V, proper DBE stacking & handling, regular cleaning checklists.
What is the goal for Order Processing & Fulfillment related to O2MFR (Order to MFR time) and what are the challenges faced?
Goal: 2.7 mins from order placement to MFR. Challenges: Improper placement of top 1200 SKUs, high walking/search time, high UPL, attrition.
What solutions are proposed to address the O2MFR challenges?
For high UPL, get pickers from nearby PODs. For 1/2 UPL, SM/Loader to login as picker. Accurate placement of top 1200 SKUs. Daily packaging audit & callout shortages. Monitor 'Pick & Pack' and coach pickers. Highlight non-working HHDs to IT. SM/ASM login during peaks.
What is the goal for handover time in Order Processing & Fulfillment and what is the key challenge?
Goal: 60 secs for DE arrival to order handover/picked. Key challenge: Unavailability of dedicated resources.
Based on the information provided, identify one people productivity/motivation challenge and a corresponding solution.
Challenge: Attrition. Solution: For high UPL, get pickers from nearby PODs to handle workload.
Study Notes
Order Processing & Fulfillment
- IGCC Goal: Clean and fresh products to customers
- Current challenges:
- Delay in removing unsellable AC, chillers, or clearance freezers from shelves
- Dirty/dusty non-adherence to FEFO (First Expiration, First Out) and reusable stacking norms
- Bags not removed by 2 am daily
- Solutions:
- Remove unsellable SKUs by 2 am daily
- Reject poor-quality SKUs at inwarding, 100% adherence to FEFO process
- Proper stacking and handling of fragile items (DBE)
Order Processing & Fulfillment - O2MFR
- Goal: 2.7 minutes from order placement to MFR
- Current challenges:
- Improper UPL and placement of attrition
- High walking/item search time
- Top 1200 SKUs not prioritized
- Solutions:
- Improper UPL and placement of attrition to be monitored
- Pickers to login as picker during peak hours
- Daily packaging audit and callout shortages
- Work with COM to correct ranking
- Highlight non-working HHDs to IT
Order Processing & Fulfillment - Handover Time
- Goal: 60 seconds for DE arrival to order handover/picked
- Current challenge:
- Unavailability and improper dedicated POD process
- Solution:
- Improper dedicated POD process to be monitored and corrected
Inwarding
- Goal: Ambient 4 hours, F&V 2 hours, Cold 30 minutes
- Current challenges:
- Inwarding delays and availability of missed GRN loaders (WH & DSD)
- Low inventory quality and accuracy
- Solutions:
- Call loaders before start of shift
- Loaders to be ready 10 minutes before vehicle arrival
- Unloading to be completed in 30-45 minutes
- Track pendency in app every 30 minutes
- Hustle loaders to avoid idle time
IGCC Goal
- Goal: Non-negotiable - POD led M+W to be ZERO
- Current challenges:
- SM unaware of picker performance
- SM RCA adherence is low
- Solutions:
- Mandate PICK & PACK for all pickers
- Picking to be done in bag/basket only
- Pickers to inform SM in case of EBM
- SM RCA to be done by 4 pm daily
- Recognize top performers, revise placement on Handler Pigeon Hole
- MFR masking solutions:
- Deploy handler for morning/evening peak
- Cross-train pickers/loaders as handlers
- Real-time monitoring of DE queuing
- SM to login as Handler if queuing is >5 DEs
Inventory Management (ACCURACY)
- Goal: 100% items at CORRECT LOCATION with CORRECT QUANTITY
- Current challenges:
- SKU count and location inaccuracies
- Cycle count task pendency
- Solutions:
- Process non-adherence to FEFO and sample audits
- Putaway at mapped locations only
- Daily cycle count tasks completion
- Daily sample audit by SM for 50 SKUs
- 100% adherence to FEFO process
- Allow picking from picking racks only
- Daily FnV batch correction before fresh stock arrival
Inventory Management (CONTROL)
- Goal: ZERO Damages & Pilferages
- Current challenges:
- Damages led LOSS
- Pilferage led LOSS
- Solutions:
- 100% adherence to Frisking Process
- SG recording
- 100% material movement
- Timely stock adjustment post Cycle count
- Accuracy Check of 50 SKUs daily
- 360-degree positioning of CCTV Camera
- Daily Gate Meeting with Loaders - Wastage Value
- Infra led LOSS
- Regular Pest Control Treatments
- Timely tickets for equipment issues
- Minimum Batch Changes
- Personal phones NOT allowed within PODs
Test your knowledge on solutions for warehouse inventory management, including placement strategies, real-time monitoring, and accuracy goals. Explore challenges such as SKU count inaccuracies, cycle count task pendency, and process adherence issues.
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