Supply Chain Associate Participant Handbook PDF

Par cipant Handbook Sector Logis cs Sub-Sector Supply Chain Occupa on In-plant logis cs, Transport Management Reference ID: LSC/Q3201, Version 1.0 NSQF level 3 Supply Chain Associate Published by Logistics Sector Skill Council Address: No. 480 A, 7th floor Khivraj Complex 2, Anna Salai, Nandanam, Chennai – 600 035 Phone: 044 4851 4605 Email: [email protected] Website: www.lsc-india.com First Edition, May 2023 This book is sponsored by Logistics Sector Skill Council (LSC) Printed in India by LSC Under Creative Commons License: Attribution-ShareAlike: CC BY-SA This license lets others remix, tweak, and build upon your work even for commercial purposes, as long as they credit you and license their new creations under the identical terms. This license is often compared to “copyleft” free and open-source software licenses. All new works based on yours will carry the same license, so any derivatives will also allow commercial use. 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The coded boxes in the book called Quick Response Code (QR code) will help to access the e-resources linked to the content. These QR codes are generated from links and YouTube video resources available on Internet for knowledge enhancement on the topic and are not created by LSC. Embedding of the link or QR code in the content should not be assumed endorsement of any kind. Logistics Sector Skill Council is not responsible for the views expressed or content or reliability of linked videos. LSC cannot guarantee that these links/QR codes will work all the time as we do not have control over availability of the linked pages. Skilling is building a be er India. If we have to move India towards development then Skill Development should be our mission. Shri Narendra Modi Prime Minister of India iii COMPLIANCE TO QUALIFICATION PACK – NATIONAL OCCUPATIONAL STANDARDS is hereby issued by the LOGISTICS SECTOR SKILL COUNCIL for SKILLING CONTENT: PARTICIPANT HANDBOOK Complying to National Occupational Standards of Job Role/ Qualiﬁcation Pack: ‘Supply Chain Associate’ QP No. ‘LSC/Q3201, NSQF Level 3’ Date of Issuance: August 25th, 2022 Valid up to: August 25th, 2025 Authorised Signatory (Logistics Sector Skill Council) * Valid up to the next review date of the Qualiﬁcation Pack iv Acknowledgements We wholeheartedly thank all the organizations who have immensely helped us in endorsing the contents of this Participant Handbook thus contributing towards Government of India's initiative in skilling based on the Qualification Pack (QP) & National Occupational Standards for a Supply Chain Associate. v Participant Handbook About this book This Participant handbook is designed to provide theoretical and practical skill training to students aspiring to become Supply Chain Associates in the Logistics Sector. It covers a wide range of topics related to the logistics and supply chain industry. The handbook includes modules that have been revised to incorporate the diversity, varied perspectives, and dynamic nature of the logistics sector. A Supply Chain Associate plays a vital role within an organization, focusing on managing and optimizing the flow of goods and services throughout the supply chain. Their responsibilities include overseeing tactical procurement functions such as sourcing suppliers, negotiating contracts, and managing vendor relationships. Additionally, a Supply Chain Associate must possess expertise in inventory analysis, which involves monitoring inventory levels, identifying trends and patterns, and ensuring the availability of the right products in the correct quantities at the appropriate time. By studying this handbook and completing the training modules, students will gain the necessary knowledge and practical skills to excel as Supply Chain Associates in the logistics sector. The content of the handbook aims to provide a comprehensive understanding of the role, enabling individuals to contribute effectively to supply chain management and its associated processes. This Participant handbook contains the following NOS: 1. LSC/N0102: Loading and Unloading 2. LSC/N3205: Handling stock at In-plant warehouse 3. LSC/N3206: Perform Line Feeding Operations 4. LSC/N9908: Maintain and monitor integrity and ethics in operations 5. LSC/N9909: Follow and monitor health, safety and security procedures 6. DGT/VSQ/N0101: Employability Skills (30 Hours) 7. LSC/N3201: Handling Leather in the Footwear Manufacturing Plant 8. LSC/N3202: Handling raw materials in the FMCG manufacturing plant 9. LSC/N3203: Handling automotive components in the automotive manufacturing plant 10. LSC/N3204: Handling components and parts in the electronics assembly plant 11. LSC/N3207: Handling raw materials in the Pharmaceutical manufacturing plant 12. LSC/N1004: Route planning and vendor coordination Key Learning Objectives for the specific NOS mark the beginning of the Units for that NOS. The symbols used in this book are described below. The Key Learning Outcomes and the skills gained by the participant are defined in their respective units. Post this training, the participant will be detail-oriented, analytical, and possess excellent problem-solving skills. They will be able to effectively communicate with all stakeholders, including suppliers, vendors, and internal teams, and be able to build and maintain strong relationships across the supply chain. vi Supply Chain Associate Table of Contents S.No Modules and Units Page No 1. Introduction to Supply Chain Associate (Bridge Module) 1 Unit 1.1 - Components and Sub-Sectors of Supply Chain and Logistics Sector 3 Unit 1.2 - Job Role of a Supply Chain Associate 12 Unit 1.3 - Activities in a Transport Yard 15 Unit 1.4 - MHEs and Equipment used in a Warehouse 26 Unit 1.5 - Documents Required in Plant Operations and Goods Transport 33 2. Loading and Unloading (LSC/N0102) 39 Unit 2.1 - MHE and PPE required for Loading and Unloading Process 41 Unit 2.2 - Managing Unloading Process 45 Unit 2.3 - Managing Loading Process 48 Unit 2.4 - Managing Exceptions during Unloading and Loading Process 51 3. Handling Raw Material at in-plant Warehouse (LSC/N3205) 55 Unit 3.1 - Introduction to Material Handling 57 Unit 3.2 - In-plant warehouse 60 Unit 3.3 - Quality Assurance 62 Unit 3.4 - Inventory Management 64 Unit 3.5 - Warehouse Maintenance 66 4. Line Feeding Operations (LSC/N3206) 71 Unit 4.1 - Introduction to Picking Process 73 Unit 4.2 - Material Handling Equipment 76 Unit 4.3 - Introduction to Kitting 79 Unit 4.4 - Line feeding operations 81 5. Guidelines on Integrity and Ethics (LSC/N9908) 87 Unit 5.1 - The Importance of Integrity and Ethics in Business 89 Unit 5.2 - Regulations governing Warehousing and Logistics Industry 91 vii Participant Handbook S.No Modules and Units Page No Unit 5.3 - Data Integrity and Security 95 Unit 5.4 - Business Etiquettes and Code of Conduct 97 Unit 5.5 - Managing Deviations in Ethics and Code of Conduct 101 6. Compliance to Health, Safety & Security Norms (LSC/N9909) 105 Unit 6.1 - Implementing Safety in the Warehouse 107 Unit 6.2 - Handling Dangerous and Hazardous Goods 113 Unit 6.3 - 5S Concept 116 Unit 6.4 - Managing Breach of Safety, Accidents and Emergency Situations 119 7. Pharmaceutical Raw Material Handling (LSC/N3207) 125 Unit 7.1 - De Dusting Procedure 127 Unit 7.2 - Introduction to Kitting 130 Unit 7.3 - Quality Assurance 133 Unit 7.4 - Labelling Procedure in Storage 135 8. Leather Handling (LSC/N3201) 141 Unit 8.1 - Leather Handling and Storage 143 Unit 8.2 - Handling process 147 Unit 8.3 - Quality control 150 9. FMCG Raw Material Handling (LSC/N3202) 155 Unit 9.1 - Introduction 157 Unit 9.2 - Good Movement Processes 160 Unit 9.3 - Inventory Management 163 Unit 9.4 - Reporting and Communication 167 10. Automotive Component Handling (LSC/N3203) 173 Unit 10.1 - Component Handling Process 175 Unit 10.2 - Standard Operating Process 178 viii Supply Chain Associate S.No Modules and Units Page No Unit 10.3 - Inventory Verification 181 Unit 10.4 - Reporting and Communication 184 11. Electronics Component Handling (LSC/N3204) 189 Unit 11.1 - Component Handling Process 191 Unit 11.2 - Standard Operating Procedures 195 Unit 11.3 - Line Feeding 198 12. Route Planning & Vendor Coordination (LSC/N1004) 205 Unit 12.1 - Route Planning, Scheduling & Optimization 207 Unit 12.2 - Why Route Planning? Route Planning Software 209 Unit 12.3 - Job Role / Activities & Vendor Coordination 212 13. Employability Skills (DGT/VSQ/N0101) (30 Hrs.) 217 Employability Skills is available at the following location : https://www.skillindiadigital.gov.in/content/list Scan the QR code below to access the ebook 14. Annexure 219 ix Participant Handbook x 1. Introduction to Supply Chain Associate Unit 1.1 - Components and Sub-Sectors of Supply Chain and Logistics Sector Unit 1.2 - Job Role of a Supply Chain Associate Unit 1.3 - Activities in a Transport Yard Unit 1.4 - MHEs and Equipment used in a Warehouse Unit 1.5 - Documents Required in Plant Operations and Goods Transport Bridge Module Participant Handbook Key Learning Outcomes By the end of this module, the participants will be able to: 1. Describe the components and sub-sectors of the supply chain and logistics sector 2. Explain the job role of a Supply Chain Associate 3. Demonstrate the activities in a transport yard 4. Describe MHEs and equipment used in a warehouse 5. List the documents required in plant operations and goods transport 2 Supply Chain Associate UNIT 1.1: Components and Sub-Sectors of Supply Chain and Logistics Sector Unit Objectives By the end of this unit, the participants will be able to: 1. Describe the Supply Chain and Logistics Sector in India 2. List the components of the supply chain and logistics sector 3. Describe the sub-sectors of the supply chain and logistics sector 1.1.1 Introduction to Supply Chain and Logistics Sector One of the essential factors influencing a nation’s economy is its Logistics sector. This sector comprises procedures regulating the accumulation, storage and delivery of items at desired locations. Monitoring the effectiveness of various suppliers and distributors is one of the prime functions of the Logistics department. This sector is a very unique and important sector influencing a nation’s exports. As a result, the robust nature of this sector always provides a competitive advantage to any country. The Logistics sector includes all kinds of supply chain operations in which stock management, customer service, data transfer and transportation are the most important ones. This sector not only ascertains the growth of a nation’s supply chain but also allows it to make a big impact in the global market. The efficiency of this sector reflects organisations' ability to cope with the daily demands of the market. Logistics Sector of India Over two crores and 20lakhs of people in India depend on the Logistics sector for their income. It is assumed that around 15 per-cent of the total GDP is achieved from this sector. The department for the Logistics sector of India was founded on 7th July 2017. This department was bestowed with the responsibility of managing the growth of the Logistics sector in India. The Special Secretary of the Indian Government heads this department. He has been given the huge responsibility to create a strategy of action to simplify the entire growth of the Logistics sector by changing policies, improving existing methods, identifying and resolving problems and adjusting to modern technology. The logistics sector of India comprises ten thousand products, five hundred certifications, forty participating government agencies and thirty-seven promotion councils for export. The estimated value of the Logistics Sector of India was around hundred and ninety billion US Dollars in 2019. This sector is unorganised, and it mainly comprises small-scale warehouse owners, truck owners with two or three trucks at the maximum, transport organization brokers, brokers of customs, goods packers and movers etc. The growth of the Indian Logistics sector is clear from the all-world survey of longevity in trade conducted by the United Nations Economic and Social Commission for Asia and the Pacific in the year 2021, where India achieved 90.3 per cent. It was a huge growth compared to 78% back in 2019. 3 Participant Handbook Role of the Indian Government towards the growth of the Logistics sector The government of India has implemented various steps to enhance the Logistics sector. These are as follows: Na onal Logis cs Policy STEP 1 Na onal Logis cs Law STEP 2 Logis cs Master Plan STEP 3 Na onal Mul modal Facili es and STEP 4 Warehousing Na onal Logis cs Workforce Strategy STEP 5 Fig 1.1.1: various steps were taken by the Government of India to enhance the Logistics sector 1. National Logistics Policy–This policy aims to enhance the Indian economy by setting up a cost- effective, flawless and consolidated supply chain network that utilises world-class equipment, methods and highly qualified personnel. This action plan will initiate a distinct mode of online logistics market and give importance to competitions, skill development and employment opportunities for micro, small and medium enterprises. 2. National Logistics Law–this law has already been created but is still under discussion. Through its enforcement with the help of one legal infrastructure, it will support the idea of one country, one market and one contract and initiate a flexible yet controlled environment. The provisions of this act will allow for establishing one actual logistics account number instead of multiple complicated registration procedures. 3. Logistics Master Plan–this plan of action considers geographical planning rather than an industrial process. It involves blending numerous activities and projects into one strategy to develop the amalgamation of single or multiple modes of transport. Based on this plan, the building of the required infrastructure is strategized. 4. National Multimodal Facilities and Warehousing–National Grid of Logistics Parks and Terminals are strategized to promote single-mode and multi-mode logistics parks as a separate infrastructure level and to emphasise the registry of multi-mode facilities. It is done to support planned growth, optimal utilisation and price discovery. The government has also started implementing certain rules and regulations to improve warehouse operations. The government strategizes methods for accessing permissions to make constructing warehouses easier and more effective. 5. National Logistics Workforce Strategy–the government is also designing a national logistics employee plan to develop the skills of logistics professionals. It is created based on the existing skill development infrastructure, which depends on various transportation modes. The idea is to create a transfer of ideas among professionals from multiple sectors and to produce a strong base of professionals in the Logistics sector acting as the main force in the development of the Logistics sector. 4 Supply Chain Associate The top logistics companies in India Blue Dart Ekart FedEx Delhivery DHL Logis cs Shadowfax XpressBees GATI DTDC Safe Indian Post Express Fig 1.1.2: The top Logistics companies in India 1.1.2 Components of the Supply Chain and Logistics Sector One of the most crucial sectors that every organization in India utilises in the present day to manage their supply chain activities is the Logistics sector. The process is very complicated, requiring the transfer of goods from the producer to the supplier and finally to the ultimate user. All these organizations, therefore, utilise several important components of Logistics management. Each of these components plays a crucial part in transporting goods and items. These components in details are discussed below: The top components of the Logistics sector are as follows: Components Of A Logis cs Sector Storing, Goods Goods Data Handling And Stock Packaging and Transporta on Management Warehouse Management Merging and Control Management Fig 1.1.3: Top components of a Logistics sector Storing, Goods handling and Warehouse Management–this is the first important component of a logistics company. It helps producers distribute a controlled flow of items. The producers always produce goods even when there is a low demand for items in the market. It is mainly due to the unpredictability of demand, whereas supply is steady. Organizations look to overcome this problem by producing in bulk and waiting patiently till the items are in high order. The excess items are stored away at the warehouse. These warehouses contain various storage equipment like shelves, racks, and relocation equipment to move items from one place to another within the warehouse. 5 Participant Handbook Fig 1.1.4: Storing, Goods Handling and Warehouse Management Goods Packaging and Merging – the second important component for a logistics company is Goods packaging utilised to maintain goods. It helps protect interests from taking any damage while in transit from the producers to the sellers. Further packaging also safeguards items from sustaining an injury in the seller’s place. Along with this, merging items into one unit for delivery makes transportation seamless and less complicated. It completely reduces the overburdening of articles during transit. As a result, goods packaging and merging play an important role in transporting, storing and maintaining goods. Fig 1.1.5: Goods Packaging and Merging Stock Management–the third component of the logistics sector is stock management which revolves around warehouse management and the stocking of goods. It generally comprises the kind of items, the storage site and the number of things an organization has. Stock management monitors the flow of goods in and out of a warehouse. This data can be achieved by reviewing the sales figures of the last transacting and using calculation and computing methods to assume the number of goods a customer can order. As a result, the stock can be managed according to the varying orders from the customers. Fig 1.1.6: Stock Management 6 Supply Chain Associate Transportation–Transportation is the fourth and most crucial component of the logistics sector, and it constitutes connectivity among various activities in the logistics sector. Transportation is important, from producing goods to delivering the items to the final user. The transportation method is carried out with proper strategy, incorporating ideas and tracking the flow of things in the supply chain. An organization must take care of its transportation services, as failure to deliver goods to a customer on time can create a bad impression of the items and the company. Fig 1.1.7: Transportation Data Management and Control–the final component of the logistics sector is data management and control. It is needed to maintain equilibrium among all other elements of the logistics sector. Data regarding the number of stock or orders allow organizations to plan and organise the number of items sent out for delivery and the number stored in the warehouse. It also helps in strategizing and seamlessly executing the transportation. With data collection, analysis and control, organizations can manage the execution of all kinds of operations effortlessly. It also allows an organization to understand and assume future demand and supply for any particular item. 1.1.3 Sub-sectors in the Logistics Sector The sub-sectors in the logistics sector are as follows: Warehouse Management - Inventory management, inbound material management, distribution management, and dispatch management needs are the main focus of the warehousing sub-sector. This sub secondary sector's packaging for transportation plays a significant role in the logistics sector. Fig 1.1.8: Warehouse 7 Participant Handbook Land Transport - Land transportation accounts for roughly 60% of all modes of transportation in India, followed by rail (33%) and water freight (7%). Consolidation of cargo, transport and network coordination is part of the transportation subsector. Commercial vehicle drivers (CVDs) are in short supply, particularly in the heavy vehicle sector. Fig 1.1.9: Truck (Land Transport) Express and Courier Services - In India, papers account for a sizable portion of the segment's time- sensitive and frequently high-value consignments handled by the courier and express industry. Because many businesses also provide e-commerce services, this sub-sector has high employment potential. Fig 1.1.10: Ecom Express Courier Service Port Terminals, ICD and CFS Operations - The Sagarmala Project's concentration on port infrastructure will significantly increase freight movement speed and volume while promoting economic growth. The port user community will inevitably become more consolidated, and when the new projects begin, multi-skilled, trained labour will be required. Fig 1.1.11: Port Terminals, ICD and CFS Operations 8 Supply Chain Associate Export and Import Logistics - Global currency swings impact the dynamic market in that freight forwarders operate. To organise affordable freight, they must be familiar with transportation laws, international trade documents, etc. Fig 1.1.12: Export and Import Logistics E-commerce - Commerce is the buying, selling, and transferring goods, services, money, and data over an electronic network, most notably the internet. Business-to-business (B2B), business-to- consumer (B2C), consumer-to-consumer (C2C), and consumer-to-business (C2B) interactions are the four main types of business transactions. Fig 1.1.13: Major E-commerce Players in India Air Cargo Operations - Time-sensitive and high-value cargo transit will rise with improved regional connectivity. Most courier and express organisations would utilise this regional connectivity to guarantee quicker and more dependable delivery schedules. More scattered work locations will be required as a result, which will increase demand for qualified local individuals to fill the open positions. Fig 1.1.14: Air Cargo Operations 9 Participant Handbook Cold Chain Logistics Solutions - Fruits and agricultural products must be stored in a controlled environment after harvest to avoid degradation. Like how vegetables must be properly maintained and delivered in a refrigerated environment, humidity management is crucial. "Reefer vehicles" are another name for refrigerated vehicles employed in the cold chain. Fig 1.1.15: Snowman Cold Chain Logistics Service Railway Logistics - Around 35 per cent of the freight for dense materials, such as steel, cement, and coal, is transported by rail. The preferred means of transportation is rail. However, rail transportation has seen a decline from over 75 per cent at independence to just about 30 to 35 per cent today. The competition from the road, which provides more flexibility, is primarily to blame for this. Additionally, because of an inverted freight structure, rail is less competitive for many goods over shorter distances. The track's capacity and speeds are also restricted. Passengers are given priority over interests, which causes delays and longer transit times for shipment by road. Fig 1.1.16: Railway Logistics Inland Waterways and Shipping Services - India has an approximately 7500-kilometre-long coastline, access to the sea on three sides, and 168 small and intermediate ports. While the corresponding marine state governments manage minor and intermediate ports, major ports are directly administered by the Central Government. In all maritime nations, shipping has long been considered an important part of the national transportation sector and is well suited for the inexpensive transportation of bulk cargoes. Coastal shipping is a supplemental transportation source that is economically necessary and useful in emergencies. Coastal shipping refers to the transport of freight via ship between various ports along the coastline.Coastal shipping is the most economical, energy-efficient, environmentally friendly, and clean means of transportation for commodities when compared to road, rail, and air. Waterways comprise about 6 per cent of India's transportation modal mix, which is much less than what it is in developed and some emerging nations. The building of National Waterways 1 and 2 has just started to focus attention on inland waterways over the Ganga and Brahmaputra rivers. The biggest challenge is keeping the lowest draught necessary for ships to navigate the entire span. 10 Supply Chain Associate Fig 1.1.17: Inland Waterways and Shipping Services Multimodal Transportation - When commodities are moved from point A to point B by a single transport operator using various modes of transportation, this is referred to as "multimodal transport." Multimodal transportation is a useful remedy in a nation like India, where end-to- end delivery presents difficulties. The most typical are roads. Railways are soon catching up. While air freight is expensive, inland rivers have recently begun to operate. Due to the existence of natural harbours and the economic importance of Gujarat and Maharashtra, port-led cargo traffic is disproportionately skewed towards the west coast. More private investments in logistics infrastructure with easier rules are required to support this expansion. Fig 1.1.18: Multimodal Transportation 11 Participant Handbook UNIT 1.2: Job Role of a Supply Chain Associate Unit Objectives By the end of this unit, the participants will be able to: 1. Describe the role of a Supply Chain Associate 1.2.1 Role of a Supply Chain Associate An expert who oversees the whole supply chain of a business, from the acquisition of raw materials to production, is known as a Supply Chain Associate. They need to plan storage for the goods and ensure they arrive at the right moment to ensure that nothing is lost or damaged during this intricate procedure. The supply chain strategy of a corporation is created and maintained by Supply Chain Associates. Their objective is to increase productivity and efficiency, cut expenses, and procures high- quality materials for their business. Logistics are tracked by Supply Chain Associates, who also update the company's inventory. They assess operational effectiveness and address problems. They also work closely with vendors and suppliers to guarantee that all activities (such as shipping and delivery) adhere to the highest quality and safety standards. Managing all the procedures and steps required to turn raw materials into finished goods and ensuring that they are delivered on schedule is part of a Supply Chain Associate's everyday duties. To do this, executives may need to supervise the manufacturing and then keep an eye on and track the production of supplies and goods and their shipment. Supply Chain Associates constantly monitor items and supplies to ensure that demand is met and that customers are not dissatisfied. Maintaining vigilance for any concerns resulting in shortages, delays, escalating costs, or other issues is another Supply Chain Associate duty. Executives also design delivery methods to ensure that every item reaches its destination quickly. In general, Supply Chain Associates strive to keep friction within the supply chain discipline to a minimum. Therefore the role of a Supply Chain Associate can be broadly classified under five categories as follows: Assis ng in Cost Hiring Minimiza on Dealing with Managing New Trends Risks Following Guidelines Fig 1.2.1: Roles of a Supply Chain Associate 12 Supply Chain Associate Assisting in Hiring - Although they are not the ones recruiting, Supply Chain Associates often participate in screening and evaluating potential new managers and directors. Cost Minimization - To develop ways to save costs, you will examine expenses across a wide range of supply chain components in this position. This duty also includes renegotiating alliances and other executive-level interactions. Managing Risks - An important responsibility of the Supply Chain Associate is to examine operations to identify solutions to lower risk. Failure to recognise hazards can harm the business. Following Guidelines - The executive tier frequently handles things like adhering to laws and standards imposed by the company. Executives often must examine additional aspects affecting the entire company at several levels. Dealing with New Trends - New trends and changes in the industry are always emerging. Executives need to be aware of these developments to decide whether the business has to evolve, perhaps by modernising its technology. Responsibilities of a Supply Chain Associate comprise of the following: Developing the supply chain strategy for the business To identify bottlenecks and other problems, analysing data from the shipping and delivery processes Review and present KPIs Keeping an eye on logistics to make sure they go well Up keeping of supply chain records and inventory Instructing and directing staff Finding affordable solutions for supply chain operations Fixing any problems that arise (e.g., delays in delivery, accidents) Co-creating a coordinated strategy for corporate growth with other divisions Creating and putting into effect safety policies for the whole supply chain (e.g., use of trucks and forklifts) Making sure supply chain operations adhere to regulations and standards Closing more lucrative sales, converse and bargain with vendors and suppliers Supply chain managers typically hold degrees in business, logistics, supply chain management, or a related subject. They are knowledgeable about applicable software and ERP systems and thoroughly understand supply chain operations. In general, the duties of a supply chain manager call for excellent project management and problem-solving abilities. 13 Participant Handbook The career graph of a Supply Chain Associate Managing Director/ Supply Chain - President, Vice Lead president, (Project Global/country management, head, Chief vendor general managers Supply chain development, supervisor client (project management, management) business Supply development, Chain compliance, Execu ve logis cs informa cs, process improvement, block Fig 1.2.2: Career graph of a Supply Chain Associate 14 Supply Chain Associate UNIT 1.3: Activities in a Transport Yard Unit Objectives By the end of this unit, the participants will be able to: 1. Describe the activities that take place in a transport yard 1.3.1 Transport Yard Activities Few aspects of your supply chain have as much of an impact on your company's operations as your choice of transportation. Transportation strategies guarantee that deliveries to and from your plant go without a hitch and reach their intended locations on time. It's crucial to incorporate transportation into your supply chain management strategy, given how vital it is to your company's success. Due to its significance, transportation is regarded as one of the three key elements of supply chain management. Fig 1.3.1: Transport Yards and Activities The Three Components of Supply Chain Management Three essential parts comprise a supply chain: manufacturing, transportation, and purchasing. From beginning to end, you will have to decide on numerous important issues involving these parts, such as: the products' raw materials; the volume of production; the amount of inventory; the layout of the distribution network; the transportation for both receiving and shipping; Any supply chain strategy should consider effective transportation management because it frequently gives a company a competitive edge. 15 Participant Handbook How Transportation Works in Supply Chain Management When referring to a supply chain, "transportation" describes the movement of goods from one place to another. This movement starts at the beginning of the chain, when materials arrive at the warehouse, and continues to the final user when the customer's order is delivered to their door. Because of its importance, warehouse managers should look at transportation inside their supply chains. In the end, this is the only method to reduce overall costs in a model where transportation expenses can total up to 60% of total operating expenses or a sizeable amount of a company's supply chain expenses. For transportation to take place, four components are essential: Modes - They stand in for the conveyances, which are often vehicles used to support the movement of people or goods. While some methods can carry passengers and freight, others only intend to bring one. Infrastructures - the physical infrastructure that supports transportation modalities, with routes (such as railroad lines, canals, or highways) and terminals (such as ports or airports) constituting the bulk of the system. Superstructures are moveable assets with a shorter lifespan that are also included in infrastructure. The infrastructure of an airport would consist of items like the runways, while the superstructure would consist of terminals and control systems. Piers and navigational channels make up a port's infrastructure, while cranes and yard machinery make up its superstructure. Networks–It is a network of interconnected places that serves as a representation of the geographical and functional structure of transportation. This system shows the related locations and how they are serviced. A network has some more reachable sites (with more connections) than others (with fewer connections). Flows -movements over separate networks of people, goods, and information. Flows have beginnings, middle points, and ending points. An intermediary place is frequently needed to get from an origin to a destination. For instance, travelling between airports may necessitate transit at the hub airport. 1.3.2 Yard Management System (YMS) A facility, distribution centre, or warehouse's yard and dock are both monitored by a software programme called a yard management system, or YMS. By closing the visibility gaps in your operations between transportation and warehouse, yard management systems can produce great opportunities for agility and efficiency. Yard Management In yard management, shipments, workers, trucks, trailers, and more are scheduled, coordinated, and directed inside a facility's dock and yard. Recent supply chain volatility and the complexity of yard management concerns have prompted many firms to examine their yard operations in search of possibilities to boost efficiency. A Yard Management System (YMS), a crucial yard management and optimization instrument can help in this situation. 16 Supply Chain Associate Fig 1.3.2: Activities in a Yard Functions of a Transport Yard Receiving goods trains; ᴑ Passing through trains after changing engines, ᴑ Performing a C&W inspection, removing any sick waggons, and, if necessary, adjusting the load of trains ᴑ Breaking up and sorting terminating trains and local loads that start in the yard's direction or according to their final destination ᴑ Following marshalling orders, from originating through trains to the farthest possible destination Despatch of trains; ᴑ Reception and despatch of through block loads; ᴑ Formation of shunting and van trains for various sections served by the yard; ᴑ Movement of train engines and pilots between the yard, loco, and train; ᴑ Placement and removal of goods waggons into and from various sidings, sub yards, and sidings served by the yard. Objectives of Transport Yards Quick transit ᴑ Accepting trains without holding them ᴑ Wagons' average detention time is being reduced. ᴑ Block loading to the farthest location. ᴑ Ensure that the marshalling is correct and that trains should depart at the appropriate time. ᴑ Prompt delivery and positioning of waggons to the yard's c&w depots, sidings, and transhipment and repacking sheds Economy ᴑ Maximising productivity of resources, shunting locos, track including humps ᴑ Optimise trailing load of wagons Safety ᴑ Ensuring very less damage to waggons, assembling safely, and practically no accidents in the yard during the shunting process. 17 Participant Handbook Activities involved Bringing in trains – Collaboration between Assistant Yard Master – nomination of road, Cabin ASM, Shunting Master Dispatch of incoming locomotive without any delay – Delays may occur due to faulty layout, uncoupling porter not attending in time The inward number taking – TNCs track wagon numbers by making entries in handbooks and note down in wagon exchange books. If a reliable teleprompter is available, no inward number taking is necessary. Automatic Car identification and CCTV are new techniques of number taking. Inward Train examination – To perform an intensive C&W investigation of incoming trains, sufficient TXR personnel must be hired on the reception lines. By doing this, the amount of graffiti on departing trains is minimized. Reception lines themselves need only minor maintenance because placing carts on sick lines causes significant delays. For this, convenient amenities must be available on the reception lines: lighting, clear routes, storage of C&W material, and portable welding equipment. Sorting of Trains ᴑ Cutting-list preparation ᴑ Cutting is being uncoupled at hump yards as the cargo is being pushed over the hump. ᴑ Repetition of proper signalling at reception lines is used to control the speed of humping locomotives. In a hump cabin, points can be switched to or operated manually or by power. ᴑ The height of the hump must be sufficient to allow the worst-rolling waggon to pass at least the facing point and fouling mark. ᴑ Speed control is important because waggons' roll capacities vary. It causes successive cuts to collide before they split, waggons to stop before passing a facing point or fouling mark, and waggons to crash into one another. ᴑ Manual handbrakes, skids, mechanical retarders, and other factors can all affect speed. Despatch ᴑ Trains are dispatched directly from sorting lines if there is no separate despatch yard. ᴑ Outgoing train inspection and safe-to-run inspection ᴑ In addition to inspecting the waggons for defects, guarantee continuity and efficient brake power. The load is fit if a train has at least 85% effective cylinders available. ᴑ Outgoing number taking - VG is prepared based on this Attaching outgoing engine and taking over by GDR ᴑ Guards are required to report 30" before the departure of through goods trains, ᴑ check loads with VG, and ensure that pocket labels and seal cards are intact ᴑ Guards are also required to seal defective waggons in the presence of RPF and check them at the next station if facilities are available. ᴑ Guards are also required to check couplings for tightness and to ensure that loads in open waggons are securely fastened and that proper marshalling is carried out following current instructions. ᴑ Guards must also check separate bypass yards deal trains that do not require shunting. If not provided, it is dealt with in Reception Yard or Despatch yard. A short line shall be provided in the bypass yard to detach sick wagons if any ᴑ Trains unloading items must be marshalled according to the stations they will serve, usually in a separate grid yard or at the end of sorting lines. 18 Supply Chain Associate 1.3.3 Yard management challenges While every company is unique, many logistics organisations struggle with certain common yard inefficiencies. And, commonly, most of them originate in manual activities, as stated by nearly half of the respondents to the 2021 Yard Management Industry Report (numbers slightly vary among industries). Gate operations take too long and result in queues A busy yard frequently has a severe bottleneck caused by manual check-in and check-out procedures because it takes too long for vehicles to enter or exit. You're surely familiar with the scene when a guard is circling the guard station repeatedly, checking vehicle details and calling the dock team. Drivers may face fines while waiting in idle trucks, which wastes time and fuel. The line that forms, as a result, spills out onto nearby streets. The anticipated outcomes include detentions that pile up, delays in shipments, and dissatisfied carriers. The efficient tracking of merchandise that enters and exits the yard is not even a topic here because it takes too much time and is ineffective when done on paper. Dock activities and personnel are hard to schedule The loading dock operations are the most important methods within the yard activities, so you want to have the best performance and efficiency possible. But because interruptions tend to occur there most frequently, it's also the weakest link. As a result, it is important to make an effort to establish and adhere to the ideal timetable. Manual scheduling is never ideal because so many options need to be taken into consideration for the best planning, such as Approved trailer type Transport mode (refrigerated, fake, oversized, etc.), Package design (palletized or not), The tools required for loading and unloading, Load/unload time, The capacity of docks and warehouses, Unfortunately, we all know how easily things go wrong in transportation. Even a minor delay or one missed appointment can destroy a perfect schedule. So, without having real-time information and close to no visibility into dock activities, it’s almost impossible to react timely to disruptions and bring order back when everything’s getting out of hand. Another related problem is staffing. Inefficient personnel planning leads to either staff shortage (delays, nonfulfillment, and costly overtime) or overstaffing (resulting in staff idling and extra labour expenses). If manual scheduling is all that is used, accurately avoiding both extremes and allocating human resources is an art that is hardly ever attainable. Checking Yards and Finding items are time taking and can eventually result in losses For smaller businesses where you can view the entire region, managing assets might not be a problem. Still, if you work in a large yard, you undoubtedly already know about this difficulty. Regardless of whether you use trucks from your fleet or those from a third party, you must be able to quickly access the necessary inventory and know exactly which trucks are located in your yard. Tracking equipment -It's a complete mess if you don't know what equipment you have on hand, which truck needs to be loaded next, or even whether it's even in the yard. It was cited as their top concern by 47% of respondents in the retail sector. While carriers occasionally drive directly up to 19 Participant Handbook dock doors, most of the time, the trailer must first be parked before being moved to the proper pier by a yard truck. Many facilities conduct their yard checks manually, which is labour-intensive and prone to mistakes. And frequently, the data has already become outdated by the time such a check is completed. Fig 1.3.3: A spotter/yard truck/terminal tractor/switcher Tracking inventory - Another frequent cause of delays is poorly managed inventory, which doesn't apply to facilities that operate in a cross-docking scenario. Spotters' frustration frustratingly causes schedule changes and overtime at being unable to locate the necessary assets in the yard. Also, shipping perishable goods could result in product degradation and additional losses. The inability to perceive the big picture and not using the data produced in the yard may be other yard management issues. Now that we know the major problems, let's examine the advantages of YMS software. Optimization opportunities offered by YMS implementation Like any other system, a YMS's primary advantages are automation, synchronisation, and real-time operational visibility. From entering the gate to loading and unloading and ending with departure, it aids in the organisation and management of yard procedures. Gate management Undoubtedly, different facilities have varied security standards and check-in and check-out processes. However, the process might go faster and with fewer errors if you use the YMS gate management feature. Fig 1.3.4: Gate Management The initial stage in optimization is to replace fixed computers with portable mobile devices and paper journals to reduce the time needed to move between the truck cabin and the guard shack. 20 Supply Chain Associate Implementing a self-service portal at the gate is the next update. Even though it requires a little more time than a fully automated system, it is still far more effective than manual labour. The cargo information is connected in advance to vehicle data via the appointment management module. Visitors self-register and then receive a ticket with instructions on where to park or which dock to go. YMS then alerts supervisors or dock staff that a truck has arrived. Another choice is an automated gate. It uses RFID technology to confirm the arrival and departure of equipment, comparing the collected data to that previously obtained from the shipper or carrier. It allows authorised trucks to enter the property and prevents an unauthorised truck from leaving. As part of tracking and security systems, YMS assists in maintaining an accurate and thorough log of gate activities. Additionally, it is now feasible to instantly scan arriving and exiting items using RFID and Bluetooth Low Energy (BLE) technology, supporting the inspection process and ensuring security. Dock management Dock operations can be planned to greatly boost throughput while minimising congestion, delays, and expensive detentions. If you use a cross-docking strategy to reduce the turnaround time, efficient and dynamic scheduling is crucial. Fig 1.3.5: Dock Management In this case, the appointment management feature is the first step toward improvement, saving you from making pointless phone calls and sending endless emails. Carriers and shippers should be able to self-schedule (and, if necessary, reschedule) appointments using the implemented solution, which should display the available time slots. Pre-planned appointments are then linked to the dock scheduling tool within a YMS. The timetable is made after considering the abovementioned restrictions, assigning vehicles to docks for loading or unloading, and allocating people and necessary equipment. Prioritization can also be configured, allowing hot loads to be controlled first. Additionally, you can grant carriers access to your YMS. They will then receive the required alerts and instructions. All of the stakeholders' actions will be coordinated as a result. The process can then be tracked with real-time updates of trailer and shipment to ensure prompt response to potential disruptions. Additionally, certain integrated carrier apps provide access to digitally load paperwork, reducing the time needed. 21 Participant Handbook Asset management By enhancing visibility, YMS automates tracking assets (equipment and cargo) and makes finding and handling them easier. As they offer greater precision, guarantee security, and have longer battery lives than GPS, real-time location systems based on RFID and BLE technologies outperform it. Fig 1.3.6: Asset Management In essence, information from RFID tags and BLE beacons affixed to goods is stored and transmitted to your system when scanned by a reader (BLE beacons can even track the temperature for sensitive drugs or items and creates alerts if the thing nears the expiration date). The advantage over barcodes is that even when the tags are hidden from view, the reader may still access several titles at once. Instead, the tags inform the system of their precise, real-time location. The main expenses in yard operations are related to supervising yard trucks and the drivers who drive them. Modern YMS systems aid in optimising each trailer move by boosting spotters' productivity and lowering associated costs. The system should automatically assign tasks to spotters when trailers or goods have to be transferred to dock doors, depending on the location of the yard tractor, to cut down on trip time. Instead of using traditional phone or radio communication, spotters now receive, accept, and confirm such commands through in-cabin mobile devices. With YMS, you may create specific alerts for quick responses to potential issues or even for prevention. Hot load emergencies, underutilised leased equipment, ineffective spotter time, late departures and arrivals, detention fees, damaged trailers, etc., are such potential concerns. The necessity for manual inspections is diminished or eliminated by automated asset tracking, which also increases security and safety. Therefore, employees are spared from searching the yard or looking around for a lost item. Reporting and analytics We have a lot of articles outlining how crucial it is to use data to make better decisions and get a competitive edge. The truth is that information gathered in the yard is frequently disregarded and wasted today. However, the YMS enables you to transform unprocessed data into useful insights. The specifics of your everyday activities can be displayed in a single, understandable manner using custom reports. Additionally, YMS aids in tracking performance data to identify problem areas, spot chances for optimization, and select a carrier with greater knowledge. The following are some KPIs you can monitor to understand a business better: Gate metrics: ᴑ Percentage of total transactions by type of transaction (arrival, departure, turning away) 22 Supply Chain Associate ᴑ Transaction percentage and volume by load type (drop, live, bobtails, visitors) ᴑ By equipment status (empty, loaded, partial, tapped), the rate and number of transactions are broken out, etc. Spotters metrics: ᴑ Number and percentage of tasks by type (dock bump, manual move, pull, spot) ᴑ A typical task takes ᴑ The average amount of work each driver, does ᴑ Trends regarding downtime Carrier metrics: ᴑ Percentage of deliveries made on time, early, or late ᴑ Detention standards Equipment metrics: ᴑ The volume of shipments by weekday ᴑ Dwell time by kind of equipment ᴑ Average load time delay ᴑ Equipment percentage and number by type of load (drop, live) ᴑ rates, numbers, etc., of various types of equipment YMS integration options Creating a seamless connection with other software you use is critical to get the most out of your YMS. A dependable data exchange made possible by such integration will increase accuracy and decrease the need for manual entry. YMS can be integrated with company management systems like ERP, WMS, and TMS, as we've already said. Most YMS suppliers offer open APIs to create a two-way data flow. Purchase order information may be included in the incoming data from WMS or ERP, and the TMS may share the ETA or vehicle information. Updates to the inventory may be included in the data provided to WMS, and appointment information may be transmitted to TMS. In case there is already one and the organization don't intend to replace it with a comprehensive system, connecting the YMS to a standalone solution that delivers narrowly targeted capabilities is also crucial for efficient data sharing. It could be a business intelligence tool, dock scheduling software, gate security system, or appointment manager. Your business model may call for continuous data sharing and communication with your partners, such as carriers, shippers, 3PL firms, etc. Building connectivity with their systems makes sense so that information about orders, appointments, and updates can be sent effortlessly. We also noted how mobile devices, tablets, and portable scanners could speed up activities; thus, integrating them into a single system can boost productivity and make communication easier. Any yard process, including gate operations, dock activities, yard checks, spotter moves, etc., can use such devices. IoT devices are increasingly being used, including cameras, sensors, telematics equipment, drones, etc. By integrating these systems with your YMS, you can automate more tasks, increase your level of control, and gather additional data for examination. 23 Participant Handbook Main YMS providers There are numerous standalone software programmes with a yard management focus. We won't go into great detail about all the top YMSs because we are not trying to promote any one provider in particular. A high level of automation is provided by PINC, a complete and highly scalable yard management solution, across all key areas of operation, including gates, docks, and the yard. It emphasises using sensors and offers various reporting options to help with analytics. FourKites is a significant supplier of various supply chain tools, having partnerships with well- known companies like Walmart and Coca-Cola. Ensuring end-to-end real-time visibility is the major focus. A strong appointment management system from FourKites promises versatile integrations and simple deployment. C3 Solutions provides two distinct modules: C3 Yard for yard administration and C3 Reservations for dock scheduling. C3 Reservations is an effective solution that enables users to operate through a mobile app, attach documents, set up various notifications, apply multiple limits to the scheduling process, and much more. Users can choose the required functionality and establish custom alarms, user access, business rules, exceptions, etc., in the C3 Yard, which is simply adjustable. The Gate Module, Appointment Schedule, Dock Module, Spotter Module, Yard Check Module, asset tracking, Birds Eye View for yard visibility, Inventory and History Reporting, and more are all included in Yard Management Solutions. Additionally, a possible savings computation using their YMS is shown on their website. Main approaches to YMS implementation YMCA often needs various equipment, like sensors, mobile devices, scanners and software. Therefore, there are numerous methods to solve problems in a yard. They are: YMS functionality as part of WMS - Today, many WMS/ERP providers offer yard management capabilities within websites. They won’t provide a high level of visibility and customization; however, they will be able to meet some of your needs. Separate dedicated tools - You can have a unique need and not want to automate all yard operations, or your WMS might not have all the features you need. For instance, you might only wish to use an appointment manager or dock scheduler. You can select a specific piece of software specifically designed for this situation and integrate it with your current system. Standalone YMS solution- You can be certain that software created to address a particular issue will give you additional authority and control over your operations. We've provided a list of a few suppliers who offer comprehensive solutions for all facets of yard management. Custom development- Each firm has a unique set of requirements, and industry-specific priorities and operating models differ. For example, cross-docking models for retail firms emphasise speed and appointment management, whereas inventory management features are more important for industrial facilities. An expert company's custom-developed product guarantees maximum efficiency and meets your particular needs. The future of the yards The global digital transition impacts all industries, and logistics is no exception. Automation is inevitable, even while yards lag with their primarily manual procedures. Autonomous vehicles and IOT drones will soon alter the yard environment. Even though it may sound futuristic, it soon becomes a reality as more businesses recognise its advantages and ease. 24 Supply Chain Associate Drones equipped with BLE and RFID scanners can act as RTLSs, instantly scanning vast areas of tightly packed goods and locating the required inventory. Additionally, yards offer the ideal regulated environment for the use of self-driving cars that enable the automation of repetitive, boring yard tractor tasks. The idea of autonomous vehicles is being developed by several businesses to help reduce operating expenses. 25 Participant Handbook UNIT 1.4: MHEs and Equipment used in a Warehouse Unit Objectives By the end of this unit, the participants will be able to: 1. Describe the MHEs and Equipment used in a Warehouse 1.4.1 Material Handling Equipment (MHE) used in a Warehouse Warehouses necessitate a wide range of material handling equipment, from the most basic shelf to the most complicated lights-out facilities (warehouse automation that can operate in the dark). Although there are many different types of equipment, they may all be grouped into four major categories. Material handling is the loading, unloading, and moving of items within a factory or warehouse with the help of mechanical equipment. Therefore, "material handling equipment" refers to machinery used to move and store commodities in a warehouse. Types of MHz 1. Storage and Handling Equipment - The simplest kind, which is so fundamental you might not even consider it equipment; between receiving it and shipping it, you store your material on these shelves and racks. They are frequently designed to maximise vertical space so that the warehouse can hold more goods. This category includes bins, drawers, stacking frames, flow racks, cantilever racks, and mezzanines. Fig 1.4.1: Racks, Cantilever Racks, Mezzanines, Stacking Frames 26 Supply Chain Associate 2. Bulk Material Handling Equipment - this is control of materials, storing and transportation of items in loose bulk form Stackers and Reclaimers: Large equipment is used to drop items into stacks and pick them back up. Since it can be challenging to picture them, here is an animation of one in action. Fig 1.4.2: Stacker and Reclaimer Hoppers: Think of a large metal funnel that can release a precise amount of material from the bottom after storing it. Fig 1.4.3: Hoppers Grain elevators: grain-storage structures. They consist of several buckets on a track that carries grain to the system's top, which can automatically be directed into various silos. Fig 1.4.4: Grain Elevators 27 Participant Handbook Bucket elevators: This machine uses buckets to move massive volumes of material, much like a grain elevator. Fig 1.4.5: Bucket Elevators Conveyor Belts: belts that move while moving the material. More complex conveyor systems can be built by combining them; these are called "engineered systems". Fig 1.4.6: Conveyor Belts Dump Trucks: This is a kind of industrial material transport vehicle. Fig 1.4.7: Dump Truck 28 Supply Chain Associate Screw Conveyor: a rotating object in the shape of a screw inside a tube. Fig 1.4.8: Screw Conveyor Rotary car dumper: This mechanism rotates a train car, so its contents fall out. Fig 1.4.9: Rotary Car Dumper 3. Industrial Trucks - These are machinery or vehicles used for moving materials, and they are occasionally operated by employees and occasionally automatically. Industrial trucks and automated guided vehicles (AGVs) fall under "engineered systems." Hand trucks: They are also referred to as dollies. They are straightforward L-shaped devices that allow for tilted material transport. Fig 1.4.10: Hand Trucks 29 Participant Handbook Side-loaders: These machines transport materials into confined spaces when conventional trucks would be too wide. Fig 1.4.11: Side-Loaders Pallet trucks: Pallets can be moved using hand-operated or electric machinery that slides onto pallets. Fig 1.4.12: Pallet Trucks Walkie stackers: Although they don't have a seat for the operator, these machines move and raise pallets similarly to forklifts. They are offered in powered and manual varieties. Fig 1.4.13: Walkie Stackers 30 Supply Chain Associate Order pickers: These vehicles raise the worker to pick up tall packages off the ground. Fig 1.4.15: Order Pickers Platform trucks: Similar to a dolly but has a wider platform. Fig 1.4.16: Platform Trucks Forklifts: these are vehicles utilised to lift and transport heavy items. Fig 1.4.17: Fork Lift 4. Engineered Systems - This category of material handling equipment typically entails more intricate systems with several parts, such as automated warehouses. AGVs, conveyor belts or robotic delivery systems (complex systems that come in various sizes and shapes), or Automated Storage and Retrieval Systems (AS/RS), which are automated systems that frequently incorporate AGVs and make warehouses more efficient, are a few examples. Anything that moves materials around the warehouse so workers don't have to, is an example of this type of system. The most expensive and intricate equipment category frequently combines components from other categories into larger, more widespread systems. Before investing in these systems, a lot of effort and research is needed. 31 Participant Handbook Fig 1.4.18: AGVs, Automated Storage and Retrieval System, Robotic Delivery Systems etc. 32 Supply Chain Associate UNIT 1.5: Documents Required in Plant Operations and Goods Transport Unit Objectives By the end of this unit, the participants will be able to: 1. Describe the Documents Required in Plant Operations and Goods Transport 1.5.1 Documents Required in Plant Operations and Goods Transport Documentation in a Plant A facility with complex mechanical engineering, like a power plant or a factory, often includes various unique parts. The plant paperwork, which comprises all significant individual data, is required to operate this facility successfully and safely. In English, "plant documentation" is also referred to as "as- built documentation." By definition, this contains all the paperwork required for the plant to operate safely. There are only two secondary kinds of plant documentation. All correspondence from the tendering stage up until the commissioning of a plant is included in the project management paperwork. Dates, expenses, and resources are all included. The technical documentation takes up the majority of the second half. Numerous sub-forms for plant construction are formed by the notion alone. All applications, notices, and conditions are included in the approval papers. Construction instructions, component manuals, and electronics and control technology documentation are all included in the implementation documentation. The quality documentation includes test results and hazard evaluations. More detailed operational documentation is available. It consists of components installation instructions, operation manuals, commissioning documentation, and declarations of conformity. An operating manual that comprises work instructions for the staff is then presented. It takes considerable planning ahead of time to produce system documentation. When designing a plant design phase, the documentation cycle is divided into four stages: ongoing data gathering, raw documentation production, data transfer following functional testing, and final plant documentation following plant commissioning. This procedure's final documentation comprises three components: paper documentation and a digital version, CAD files and databases, and technical plant data for plant descriptions. The documentation for the plants is continually updated and maintained. Therefore, it is not "completed" with the plant's commissioning; rather, it continues to grow throughout its life cycle. Whenever parts are exchanged or bought, it needs to be documented. Criteria a Plant must meet When developing plant documentation, adhering to a few recommendations and rules is crucial. A language must first be defined. It's critical to agree on one or more target languages if components are sourced from different nations and supplier documents are written in many tongues. The structure of plant documentation must be uniform. The first step is naming electronic folders, files, and documents. 33 Participant Handbook Next, font sizes and types are used, and finally, colours. The emphasis in the industry is on digitization. Therefore, electronic technologies should be used for internal document management. To streamline the workflow as much as possible, digitising analogue documents such as drawings, technical graphics, and text documents make sense. The plant documentation must be classified so the plant operator can import the finished documents into his document management system. Plant documentation should be provided with references to the various sections of the documentation and specific keywords because it is frequently fairly lengthy. The maker is responsible in the event of damage, so he must make sure the paperwork is accurate. He must also keep a copy of the final documentation on file for ten years after the installation has been turned over. Documents in Goods Transport Commercial Invoice - One of the most crucial documents when exporting goods by the ocean is the commercial invoice, which is the invoice sent to the buyer by the seller (exporter or importer). To clear customs, it is necessary. Packing List - The packing list is another crucial shipping document when sending ocean freight abroad. It is a thorough description of the cargo listed on the Commercial, as mentioned above Invoice. It also contains details about the shipment's packing, including what marks and numbers are written on the outside boxes. Export/Import Customs Declaration - Details about the exported or imported products are listed in an export or import customs declaration. When transporting international freight, this notification is particularly crucial. Legally speaking, a person expresses their desire to place items under a specific customs procedure by submitting a Customs Declaration. The Declaration determines the charges or taxes charged to the goods and to clear customs. A customs broker creates it using the packing list and invoice. Find out more about how Twill can assist you with customs clearance. Bill of Lading and Sea Waybill - You will receive thorough paperwork from us called the Bill of Lading. It is the transportation contract, and it contains crucial information about the shipment. Another important component of ocean freight, it serves as evidence that the carrier has received the items from the shipper in excellent condition. The person in possession of this document also has control over the shipment. A Sea Waybill is another type of transit agreement. The Sea Waybill will only be sent out as a cargo receipt; it is not required for cargo delivery. Additionally, a Sea Waybill cannot be issued to any third parties and is not negotiable. Certificates (production, vessel, phytosanitary) - As a part of valuable shipping documents and based on the type of your cargo, the following certificates are essential to be produced when asked for: ᴑ Production Certificate: This Certificate refers to the material or categories of items made with recognised methods or sustainable resources (e.g. sustainable wood sources). The ability to transport freight into or out of areas where possible production-related laws may be in effect is necessary. ᴑ Vessel Certificate: A Vessel Certificate's main purpose is to verify a vessel's ownership, and it also provides certain details, such as the age and maintenance of the ship. The certificate is normally shown as part of the required documents for the Letter of Credit. ᴑ Phytosanitary Certificate: The Phytosanitary Certificate is a piece of evidence that guarantees plant items, as well as the plant, is free from regulated pests. It also notes that the cargo conforms to other phytosanitary requirements mentioned by the importing nation. Air or Rail Waybill - You will receive either an Air or Rail Waybill, depending on your mode of transportation. An air carrier issues the Air Waybill (AWB), a non-negotiable document, to acknowledge custody of a package. Another kind of bill of lading is the AWB. In contrast to a bill of 34 Supply Chain Associate lading, an AWB is issued in a non-negotiable form, offering less protection. The AWB also functions as the consignor's receipt (the shipper). This document includes the shipment's destination address and the sender and recipient's contact information. The Rail Waybill, in contrast, is a document used for goods made by the railroad. After obtaining the shipper's instructions, the shipping agent or railroad line prepares this document. Arrival Notice - The Arrival Notice, often known as the Notice of Arrival, is another crucial transportation document. The arrival of the cargo is announced in this document. It contains relevant information, including the description of the commodity, sailing information, destination country information on customs taxes, and the contact information of the ocean freight carrier. It is given by the destination agent of the ocean freight carrier to the consignee and any other parties who may need to be notified, as stated on the bill of lading. Certificate of Origin - The document that specifies the nation in which a thing or commodity was produced is known as a certificate of origin. It is frequently required, and this document includes details about the product, its location, and the exporting nation. It is a crucial document because it helps establish whether products are duty-free and suitable for import. Importer Security Filing (local customs requirements) - You might need to file an importer security filing for your cargo (ISF). This document is a requirement of customs and border protection that only applies to imports of ocean goods. Importers should submit the necessary information for this documentation to their customs broker before placing their shipping order since it must be filed with customs and border protection 24 hours before sailing from the last origin port. The names and addresses of the seller and buyer, the importer of record, the ultimate consignee, the manufacturer's name and address, and the nation of origin are among the information that must be provided. Letter of Credit - The main payment method in an international business transaction is a letter of credit. By default, it cannot be changed. This document represents a bank's pledge to the seller (the exporter) on behalf of the buyer (the importer) to pay the given amount in the specified currency. Additionally, it calls on the seller to deliver the required papers by a particular deadline. It also contains details like the description, the amount of the goods, the technical specifications, and the documentation needs. 35 Participant Handbook Summary At the end of this module the participants will have gained knowledge about the components and sub- sectors of the supply chain and logistics sector, the job role of a Supply Chain Associate, the activities in a transport yard, MHEs and equipment used in a warehouse and the documents required in plant operations and goods transport. Exercise Multiple-choice Question: 1. _________ safeguards items from sustaining an injury in the seller’s place a. Packaging b. Stocking c. Transporting d. None of the above 2. _________are the main focus of the warehousing sub-sector. a. Inventory management b. Inbound material management c. Distribution management d. All of the above 3. India has an approximately________ kilometre-long coastline a. 7500 b. 6500 c. 4500 d. 1500 4. The three components of Supply Chain Management are a. manufacturing b. transportation c. purchasing d. All of the above 5. The full form of YMS is a. Yard Management System b. Yacht Management System c. Yield Management System d. None of the above Descriptive Questions: 1. Describe Material Handling Equipment in a warehouse. 2. What is YMS, and how important is it? 3. What role does Transport play in Logistics? 4. Describe the documents required in Plant operations and during goods transport. 5. What are the components of a supply chain sector? 36 Supply Chain Associate Notes __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ __________________________________________________________________________________ Scan the QR codes or click on the link to watch the related videos https://www.youtube.com/watch?v=_osRX0AWLYQ 18 Raw Material Storage and Warehousing 37 Participant Handbook 38 2. Loading and Unloading Unit 2.1 - MHE and PPE required for Loading and Unloading Process Unit 2.2 - Managing Unloading Process Unit 2.3 - Managing Loading Process Unit 2.4 - Managing Exceptions during Unloading and Loading Process LSC/N0102 Participant Handbook Key Learning Outcomes By the end of this module, the participants will be able to: 1. Identify the MHE equipment used for loading/unloading for various types of goods. 2. Identify the PPE to be used for loading/unloading. 3. Demonstrate usage of hand pallet trolley, ropes/chains to secure product/crate. 4. Describe unloading process. 5. Describe loading process. 6. Explain how to manage various exceptions during loading and unloading operations. 40 Supply Chain Associate UNIT 2.1: MHE and PPE required for Loading and Unloading Process Unit Objectives By the end of this unit, the participants will be able to: 1. Identify the MHE equipment used for loading/unloading for various types of goods. 2. Identify the PPE to be used for loading/unloading. 3. Demonstrate usage of hand pallet truck and chain pulley block. 2.1.1 Material Handling Equipment As seen in Unit 1 and 2, MHE are critical for warehouse operations. The two most fundamental operations in the warehouse are loading and unloading. Warehouse is a flow through place, where inventory comes, stays for some time and moves out. Unloading and loading are continuous and everyday activities and one of the most important activity for associates. Associate needs to understand which MHE to be used for which kind of products. Fig. 2.1.1. MHE for Cartons and Pallets 41 Participant Handbook Fig. 2.1.2. MHE for different types of products One of the most frequently used MHE in warehouse to unload, move and load cartons and pallets is hand pallet truck. 42 Supply Chain Associate The following are the steps of using an HPT: Fig. 2.1.3. Steps to use Hand Pallet Truck To load and unload heavy cargo which cannot be manually lifted or lowered, warehouse uses chain pullet blocks. Following are steps in the usage of chain pullet blocks. Fig. 2.1.4. Steps to use Chain Pulley 43 Participant Handbook 3.1.2 Personal Protection Equipment As discussed in the previous section, PPE are equipment or clothing to be worn by associate to protect again the hazards of workplace. Loading and Unloading activities demands dealing with various kind of material including heavy loads. It is imperative for associate to wear appropriate PPE while conducting loading and unloading operations. Fig. 2.1.5. Personal Protective Equipment 44 Supply Chain Associate UNIT 2.2: Managing Unloading Process Unit Objectives By the end of this unit, the participants will be able to: 1. Describe the various steps in unloading process 2. Explain importance and details of every step. 2.2.1 Unloading Process Unloading is the start of the warehouse operations. It brings in the cargo to be stored, processed and further dispatched. Being the step one of the cycle, it is essential that it is done in the right manner. The scope of unloading activities start from parking of the incoming vehicle, unloading, staging, quality check, scanning, put away to the right location and finally updating the records in the system to generate the GRN. Following are the details of the steps to be undertaken in unloading process. 45 Participant Handbook 46 Supply Chain Associate Table. 2.2.1. Unloading process 47 Participant Handbook UNIT 2.3: Managing Loading Process Unit Objectives By the end of this unit, the participants will be able to: 1. Describe the various steps in loading process 2. Explain importance and details of every step involved in loading process. 2.3.1 Loading Process Loading process is the reverse of unloading process. It is the dispatch of the material from the warehouse to the final customer or production units. Loading is critical as it defines the service level to the final customer. Proper loading also ensures that there is no damage to the cargo during transit. As loading involves movement of the material outside the warehouse, it is mandatory that it is done correctly and there is no excess or short dispatches of inventory. Following are the details of the steps to be undertaken in loading process. 48 Supply Chain Associate 49 Participant Handbook Table.2.3.1. Loading process 50 Supply Chain Associate UNIT 2.4: Managing Exceptions during Unloading and Loading Process Unit Objectives By the end of this unit, the participants will be able to: 1. Explain the procedure for handling exception during unloading/loading process 2.4.1 Exceptions Management In real life and particularly in logistics operations, not everything happens as scripted. There are several exceptions which happens during the process. Following is the list of possible exceptions and the way to deal with these exceptions. Process Stage Exception How to Handle The carton found Inform the supervisor. Open the carton to check During Unloading to be open or the condition of the contents. Count the number unloading tampered of units. The incoming During material was Handle it carefully not to further damage. Segregate Unloading unloading found to be this unit. Inform the Supervisor. damaged Associate should have ideally taken preventive Associate drops measures to avoid any such occurrence. Now that During a material while Unloading it has occurred, keep the unit separately. Inform unloading unloading, which the Supervisor immediately and proceed with gets damaged. Insurance formalities if possible. The leak should be confined as far as possible. The A liquid/ leaked unit should be kept separately. In case it is During Chemical leaks a Chemical, MSDS should be immediately referred Unloading unloading during unloading to take appropriate action. Inform the Warehouse process. Manager immediately about the incident. All Safety measured should be immediately taken. If Associate finds that proper MHE is not available to unload the incoming cargo and manually During Proper MHE not Unloading unloading is either not possible or a safety concern, unloading available he should inform the Supervisor and not undertake the unloading operations. If Associate finds that proper PPE is not available to During Proper PPE not unload the incoming cargo and unloading the cargo Unloading unloading available is a safety concern, he should inform the Supervisor and not undertake the unloading operations. 51 Participant Handbook Process Stage Exception How to Handle The blind count At the numbers are not Count the pieces again. If they are still not tallying Unloading staging matching the inform the supervisor immediately. Area documented number of pieces Bar code is Inform the Supervisor immediately. The originating At the Mutilated. location need to be informed to provide the data Unloading scanning Scanning not so that Bar codes can be reprinted if possible. Keep stage possible. such units separately. The putaway location given is already carrying cargo. The Associate should not, in such a case, At the The Putaway unload at any other location. This will multiply the Unloading Putaway

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