Inbound process improvement with the help of LEAN sigma.

1. TABLE OF CONTENT
Project charter.
Cross departmental flow
chart.
SWOT Analysis on current
state.
MUDA Methodology to
Eliminate TIMWOOD Waste.
Time & Motion – Study
( Excel Data )
Outcome – Pre & Post
Analysis. Presented by:
Vivek Kr. Upadhyay,
Asst. Manager
Home center WH, Qatar

2. PROJECT CHARTER
2
PROJE
CT NAME: RE
DUCING INBOUND L
E
AD TIMEBY 35% - From Unloa ding To Put Awa y PROJE
CT MANAGE
R PROJE
CT GUIDE
NCETE
AM PROJE
CT S
PONS
OR
VIVEKUPADHYAY L
ANDL
AMKG RO UP
PHO NE
97431549186
EST
IMAT
ED CO ST
S EXPECT
ED ST
ARTDAT
E EXPECT
ED CO MPLET
IO N
15/ 04/ 2023
PRO BL
EM O R ISSUE
PURPO SE O F PRO JEC T
BUSINESS C ASE
G O AL
S / M ET
RIC S
EXPEC T
ED DEL
IVERABL
ES
WIT
HIN SC O PE
O UT
SIDE O F SC O PE
ST
ART F
INISH
11/ 04/ 2023 14/ 04/ 2023
15/ 04/ 2023 20/ 04/ 2023
27/ 04/ 2023 02/ 05/ 2023
03/ 05/ 2023 16/ 5/ 2023
17/ 5/ 2023 26/ 5/ 2023
00/ 00/ 0000 00/ 00/ 0000
00/ 00/ 0000 00/ 00/ 0000
00/ 00/ 0000 00/ 00/ 0000
Imp ro v e me nt Pha se
C o ntro l Pha se
Pro je c t Summa ry Re p o rt a nd C lo se O ut
PROJE
CTCHART
E
R - HOUSE HOL
D INBOUND PROCE
SS
K
EY MIL
EST
ONE
Fo rm Pro je c t T
e a m / Pre limina ry Re v ie w / Sc o p e
Fina lize Pro je c t Pla n / C ha rte r / Kic k O ff
De fine Pha se
M e a sure me nt Pha se
Ana lysis Pha se
Using L
EAN sig ma - T
IMWO O D, SWO Ta na lysis a nd T
IME & M O T
IO N stud y d a ta e xc e l to o ls.
Re d uc tio n in a v e ra g e to ta l time b y 35%, fro m 5.79 d a ys to 3.76 d a ys.
PR
OJECTSCOPE
T
ra ining ma np o e r, ke e p ing re q ue st ma c hine s like M HE,Fo rklift,BO PT
,HPT
, PDT
, p rinte r Etc .
ma inte nd
Re c o mme nd e d c ha ng e s in infra struc ture , p ro c e ss e lima na tio n b y IT& Auto ma tio n
T
ENT
AT
IVE SCHEDUL
E
As p e r d a ta ( O BI d a ta ) fro m Ja n23 to Ap r23, a v e ra g e 5.79 d a ys ta ke n fro m c o nta ine r a rriv a l
to Put a w a y. Av e ra g e 2.914 Da ys fro m c o nta ine r a rriv a l to re c e iv ing & 2.88 d a ys fro m
EMAIL : VIVEK.UPADHYAY@LANDMARKG RO UP.CO M O RG ANIZAT
IO NAL UNIT
WAREHO USE - HO ME C ENT
ER
EXPECT
ED SAVING S
PR
OJECTOVER
VIEW
Sp a c e issue , d e la y,Pic king d ro p o ff, imp a c t o n p ro d uc tiv ity, o p e ra tio na l e ffic ie nc y & O Tc o st.
Id e ntify & e limina te w a ste to L
EAN o p e ra tio n, re d uc e d e la ys, imp ro v e p ro d uc tiv ity &
e ffic ie nc y, re d uc e O T
.

3. Start
Mail to
schedule
container
Container
Arrived at
Warehouse
Security checks
documents &
handover to
Inbound Team
Inbound Team
takes pics pre &
post opening
container
Unloading
( Pre activities –
M,M & pallets)
Segregations,
Department wise
Receiving of goods
in system, PDT
scan
Inventory
need to make
space for
upcoming
arrivals
Put away
Physical &
system
End
Segregation need
to be done during
unloading
SCOP IN
AVOIDING LOCAL
FREIGHT UPDATE
DELAYS
TIMWOOD
analysis in last
slid
Proactive approach
from inventory
missing to manage
empty bin in
advance
INBOUND
SECURITY
INVENTORY
3
CROSS DEPARTMENTAL FLOW CHART

4.  Total time taking from
Container arrival to put
away, average days 5.79
days.
 Average days 2.91 taking
to complete activity from
container reporting till
Receiving.
 Average days 2.88 taking
to complete activity after
receiving till Put Away
4
3.32
1.97
2.72
3.49
2.88
3.49
3.16
2.37
2.63
2.91
6.81
5.13
5.08 6.12
5.79
Jan Feb Mar Apr Average
Arrival till Receiving
After Receiving to
Put Away
Total Time Arrival to
Put Away
CURRENT SCENARIO – INBOUND OPERATION

5. UNLOADING -Average Time Take for Each Box Unloading 7 Second
SEGREGATION -Average Time Take for Each Box segregation 14 second
NEW ITEM SCAN -Average Time Taking when new Item scan comes during
receiving 5 Second
RECEIVING SCANNING -Average Time rec - Scanning per box 3 second
PROCESS TIME CONSOLIDATION -Total time to complete container arrival to
receiving done in PDT 3.23 Hours.
SOME DATA FACTS -Average container arrival per day 3, average items per
container 40 ( CDC-30, CFS-48), average departments in containers CDC-3 CFS-4.
5
RECEIVING CHAIN STEPS – TIME & MOTION
1
2
3
4
5
6

6. 6
SWOT ANALYSIS ON RECEIVING
STRENGTH
 Pre information on container arrival, locals
excluded.
 Pre readiness, MAN - MACHINE – STOCK MANAGEMENT
WEAKNESS
 Receiving scanning, CTR+4 to save scanning after
every box & 3 times CTL+4 for after having item
change.
 Space related Challenges & Lack of inventory
planning.
 Segregation of Items
 Local freight update, 1 DAY gap.
THREATS
 Missing Scan – May be “Short”.
 Container scheduling – container scheduling from
CP.
 Frequent Changes in Outsourced manpower.
OPPORTUNITY
 System – Installation of Barcode reader.
https://www.youtube.com/watch?v=B-BypEEEjLU
 Stacking – Tie Hi belt to avoid transparent tap
use, do not use for Ground Label.
 Sequence changes - Receiving + unloading then
segregation for put away.
SWOT

7. 7
PUTAWAY PROCESS- IDENTIFYING TIMWOOD WASTE
TIMWOOD-
PROCESS
WASTE
TRANSPORTATIO
N
-System
Suggested 1st Bin
reference.
-Full bin, see
next
INVENTORY
- Fork lift, BOPT
Etc. in
maintenance.
MOTION
- Putting boxes on
level 1 & level 2.
WAITING
- Arrangements in
Bin
- Doing bin & Item
query.
-
OVER
PROCESSING
-
- Invalid
container ID
DEFECT
- PDT network
issue
 Average walk meter to reach next bin is 19
meters.
 Average 76 meters walk happened to complete
1 pallet put away having average 4 item
 Intersection passage in zones will help
movement reduction.
 There should be some TAT for
repair & maintenance
 Average time in place one box at Level 2
= 4.11 Second
 Average time in place one box at Level 1
= 3.36Second.
 Will be able to save 16.20%, if inventory
team plan proactively.
 Average time 6.06 send in doing Item and Bin query.
 Average twice at pallet 50 times per day. Approx 17
minutes per day, 6 hours a week.
 Will be able to save 17 plus minutes, if IT team add
some of to see balance box against transfer container.
 Average time 18.04 second to clear
this issue.
 Average time 4.42 to reconnect,
average 3 times per hour per user.

8. 8
SUGGESTION CONSOLIDATION
 Barcode scanning on conveyer while
unloading, this will help to eliminate –
1. Scanning during receiving.
2. Freight update before starting unloading
3. On time Segregation of boxes
4. Will save 2 ad hoc labors cost
 NO, to use tape for ground location boxes.
 Use of Tie- high belt instead of tap
( Suggestion from Mr. Nilesh ).
 Coordination between CP & HC before
container scheduling from CP.
 Intersection passage in zone like 2,8,9 etc.
this will help in reducing.
1. Transportation for Put away to be
reduced.
2. Picking will also have boost in efficiency
due to reduce in total walk to reach at bin
 Inventory – Bin arrangement in advance
as per mail confirmation.
 PDT device change or upgrade to avoid
“Reconnect network issue”.
RECEIVING PUT AWAY

9. 9