Focusing on Warehouse Activities, Threats & Solutions

1. H. A. DIMUTHU T. WIJESUNDARA
PROCUREMENT MERCHANDISER – VS PINK -
BRANDIX

2.  What is Warehouse ?
 A large building where raw materials or manufactured goods may be stored
prior to their distribution for sale.
Or
 A warehouse is a planned space for the storage and handling of goods and
material.
Or
 place used for the storage or accumulation of goods. The function of storage
can be carried out successful with the help of warehouses used for storing the
goods.

3.  What is Warehousing ?
 Performance of administrative and physical functions associated with storage
of goods and materials .These function including receipt, identification,
inspection, verification, putting away, retrieval, etc.
or
 Warehousing can also be defined as assumption of responsibility for the
storage of goods. By storing the goods throughout the year and releasing
them as and when they are needed, warehousing creates time utility.

4.  Types of warehouses
Private Warehouses
The private warehouses are owned and operated by big manufacturers and merchants
to fulfill their own storage needs.
Public Warehouses
A public warehouse is a specialized business establishment that provides storage
facilities to the general public for a certain charge. It may be owned and operated by an
individual or a cooperative society.
Bonded Warehouses
Bonded warehouses are licensed by the government to accept imported goods for
storage until the payment of custom duty. They are located near the ports.

5.  Overall responsibilities in Warehouse
 Receiving and unloading Goods
 Operate Equipment
 Sorting Merchandise
 Taking Inventory
 Prepare Documentation
 Store Merchandise
 Fill Orders

7.  BrandixSri Lanka’s single largest apparel exporter with an annual turnover exceeding USD 700 million
Employing approximately 47,000 Associates and generating indirect employment to an equivalent
number
Supported by 42 manufacturing facilities in Sri Lanka, India & Bangladesh and strategically located
international Sourcing Offices
Providing over 50% of value addition locally through our backward-linked operations in textiles
and buttons

8.  Warehouse structure In Brandix- Welisara
Warehouses
Fabric
Trims
Finish goods

9.  Walk around Fabric stores ..

10.  Merchandising to Warehouse
 Inquiry placing to supplier
 Quotation and details receiving
 Purchase order place
 Order proceeding
 Goods finishing
 Invoicing
 Delivering to the consignee

11.  Main activities in Warehouse
01. Get details of running order from factory
02. Coordinate with planning team and follow-up the cut plan
03. Follow-up the delivery accordingly to cut plan with Merchandiser
04. Fabric Acceptance
 An approved Purchase Order (PO) should be available in the M3 system.
 No fabric can be accepted without the PO.
 Check availability of Supplier Invoice, Delivery Note, Picking List and Customs Declaration (for
imported fabric) of the consignment.
 Reconcile invoice against the PO for Expected Delivery Date
 Accept or return consignment to supplier according to the instructions received from
procurement.

12. 05.Fabric Unloading
 Unloading should be done against to the packing list.
 3rd party security also need to verify unloading against to the packing list
 Weighing the consignment.
 This should be done just to confirm the ticket weight, It will not enter to the system & also this
should be done randomly.(25% of the consignment should be weighed)
 Sign the delivery note after unloading and hand over to the driver as a proof of fabric arrival
to the stores.
06.Documentation and GRN
 Enter unloading fabric record for daily unloading book
 Separate batch wise A4 swatches for color shade band
 Cross check supplier invoice details with PO item name
 Do the GRN accordingly to invoice
 Send invoices to finance department

13. 07.Bond with Inspection team
 Share invoice & packing details with IP team
 Handover 10% from each batch for inspection
 Taking color approval & quality approval
 Paste Yellow color sticker for all GRN batches
 Approve GRN & put away from the M3 system
08. Fabric Storing
 Store balance consignment in the quarantine area or load fabric to racks.
 Follow up and obtain the inspection result within 48 hrs. After GRN.
 Paste green colour stickers over the yellow colour sticker on fabric rolls if the batch is
approved.
 Store fabric rolls and demarcate them buyer wise.
 Get inspection department to paste red colour stickers over the yellow sticker on fabric rolls if
the batch is rejected.
 Transfer fabric rolls pasted with red colour stickers to Reject Bin, pending return to supplier.

14. 09. Fabric Relaxing
 Fabrics should be relaxed on CTEX machines and if there is an issue it should be done
manually according to the guideline given by inspection dept.
 Relax fabric rolls on manual machine if they are to be relaxed on bale (lap) form.
 Cover fabric rolls after relaxing to protect from dust and dirt.
 Keep the relaxed fabrics on relax trays/pallets and store them in their specific location.
 Write the relaxation start time, recommended duration & the end time on a tag and keep it
with the fabrics.
07. Fabric issuing
 According to the lay sheet, issue fabric to the cutting department.
 Reduce quantity from system with raising issue note

15. 10. Cutting Returns Acceptance and Storing Process
 Return excess fabrics to stores before the schedule get closed along with an email the fabric returns
excel document, mentioning the return quantity.
 Accept excess fabrics from cutting section.
 According to the return quantity reverse the issue notes.
 Store excess returns in their specific bins.
11.Maintain physical fabric accordingly to system inventory
12.Separate w/off fabric in “w/off send” & “w/off reserved” location once get
- monthly w/off report from finance
13.Create W/offs packing lists and send to BRL

16.  Threats facing in warehouse process
 Invoices & Packing lists not receiving with the deliveries
 Unexpected deliveries receiving on tide schedule
 Not enough space in unloading bay for continues unloading
 Need to keep fabric in quarantine area until get the inspection approval
 Weight variance against tag weight
 High inventory days
 Getting dirty when handling due to low density polythene covers from suppliers
 Rate difference between the PO & invoices will identification after GRN fabric

17.  Same color, close appearance quality fabric mixing when storing
 Same quality , same color fabric using from 2 CBU’s
 No enough capacity for fabric relaxing
 Fabric issuing to cutting for lay sheets and have to separate fabric rolls yardage by
yardages as per the requirement
 Wrong quality fabric issuing for cutting
 Returning fabric not physically tally with the balance rolls tag quantity
 Difficulty of tally up inventory with physical quantity
 Keep w/off reserved fabric for 3 month time and loosing space

18.  Solutions and suggestions to avoid threats
 Invoices & Packing lists not receiving with the deliveries
Requesting and make policy of send invoices/ packing lists soft copy via mail before goods
receive to the stores
 Unexpected deliveries receiving on tide schedule & Not enough space in unloading bay for continues
unloading
Merchandiser should give the prior delivery schedule for arrange the unloading capacity
 Need to keep fabric in quarantine area until get the inspection approval
Get supplier internal inspection report and shade bands with delivery

19.  High inventory days
Accept delivery only 7 days prior for the production date
 Getting dirty when handling due to low density polythene covers from suppliers
Requesting high density polythene cover or carefully handle with more manpower
 Rate difference between the PO & invoices will identification after GRN fabric
This is happening due to lack of knowledge about the system and importance of check
unit price value in PO & Invoice.
 Same color, close appearance quality fabric mixing when storing
Soring according to tag details and separate location with notice

20.  Fabric issuing to cutting for lay sheets and have to separate fabric rolls yardage by yardages as
per the requirement
Issue total requirement at once for relevant style/schedule and arrange space to maintain
their own stock with responsibility
 Wrong quality fabric issuing for cutting
Cross check with approved QA hanger before issue the fabric and need to keep QA
hanger with issuing team
 Difficulty of tally up inventory with physical quantity
Introduce WMS process and maintain discipline
 Keep w/off reserved fabric for 3 month time and loosing space
Reduce keeping time and get action to move useless fabric for w/offs send stock to
coordinate with Merchandiser

21. Thank you