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Warehouse Organization (KRISHNAIZATION) View More Case Studies

An After-Market Warehouse of a leading Automobile Company managed by a leading 3PL Company

Project was to make the huge warehouse organized, improving productivity of UC operation and reducing bin denials by 50% or more. Project Duration: 6 Months

Over and above, the objective was to make space and accountability for New Parts and creation of SOP’s to track KPI’s.

Typical results which could be achieved were: a) Reorganization of Interior Stores of about 50,000 parts and packaging materials, b) Root cause analysis and onset of Productivity Improvement in UC, c) Root cause analysis and reduction of bin denials by about 50%, d) Work Place organization for better 5S through streamline material flow, e)

Creating space and arrangements for proper storage and accounting of New Parts, f) Creation of critical SOP’s etc.

Basic activities taken up were 5S, 3-Fixed & Visual Control, Introduction of 2-Bin Concept, Flow Production system, FIFO etc., innovation in storage practices, planning & monitoring activities etc.

A Warehouse in a leading Automobile Company

Project was to organize warehouses with concepts of 3-Fixed and Visual Control in the Chassis and Engine Shops with stocks in excess of Rs. 250 Cr. The ultimate objective was to make better management of inventories and its gradual reduction.

Project Duration: 6 Months

Typical results were a) Organized Stores with 5S & Visual Control in place, b) Disposing off of Non-Moving / Dead Stocks to the extent possible, c) Accounting all cases concerning Excess Inventories and better control of Purchases, d) Proper Stacking of all items with concept of 3-Fixed, e) Up-gradation of Racks, Shelves, Bins etc., f) Safety of Materials through effective use of "USE ME FIRST" Tags apart

from better stacking, g) Pouching for ease of counting, stacking and issue of smaller parts and hardware’s, h) Driving improvement of packaging at suppliers’ ends etc.

As per latest information, inventories have come down to well below Rs. 200 Cr. Which means over 20% reduction.

A Warehouse in a leading Machine Building Company

Project was to organize some rather messy and challenging warehouses with huge varieties of items. Primary aim was to make it possible to find goods promptly for supply to the Assembly and other Shops.

Project Duration: 12 Months

Typical results have been an enviably World-class Storage system with superb 5S, 3-Fixed and Visual Control.

A Leading Switch & Socket Manufacturing Unit

Project duration: 6-Months

Project was to upgrade and reorganize warehouse for increased performance avoiding customer complaints about wrong dispatches as a part of Lean deployment program. Duration: 6 Months

Results achieved were: a) Clean, tidy & a Visual Warehouse, b) In-built FIFO, c) Increase of Productivity by 40-60%, d) Sharp reduction in Customer Complaints, f) Implementation of Quantity Control for effective Inventory Management.

Typical activities taken up were: a) Cycle Time study & improvement, c) Rationalizing work contents of operators for better utilization, d) Material feeding

frequently @ one hour by Water Spider, e) Improvement in packaging of outsourced items to facilitate direct material feeding, f) Employing concept of 3-Fixed in Stores including adoption of FIFO Tags & Quantity Control System, g) Streamlining Packaging & Dispatch process etc.

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