Welcome To Presentation By D.V. Vora Sr.General Manager & Head - Logistics & Supply Chain Email :
[email protected] GODREJ & BOYCE MFG.CO.LTD., Vikhroli
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SUPPLY CHAIN IN CONSUMER DURABLES
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SUPPLY CHAIN PROCESS - CONSUMER DURABLES For Made To Stock
Branch Forecast
Consolidation at H.O.
Mfg Plant
Stock
Customer
Warehouse
Despatch
Allotment 3
BEST PRACTICES
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Sea Transportation
MULTIMODAL TRANSPORTATION
T
Designed Multi Mode ( ROAD + SEA + ROAD) movement through Shipping Line Deferment of additional WH need by halting containers at ICD
AN SI
Mohali
DA YS
TR
Benefits
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Increase Vehicle Availability Halting at ICD and dispatch from ICD Mundra
Kandla
as per market requirement No Need of Large WH space ( Red’n
Mumbai
in Inv of 15 days)
IT NS RA ST AY 4D
Due to Container Movement - Damage reduction in transportation
g) (Av
V Kochi
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MULTIMODAL TRANSPORTATION
Rail Transportation
Movement of Full Rail Rack from Mohali factory to Kolkatta
Loading in Container
Unloading Container On Railway Rack
Mohali Mohali Station Station
Unloading At Rly
W/H
Shalimar Shalimar Station Station
Rake loads - reduce dependency on traditional transportation - vehicles available were used for other locations - no untoward hike on freight is demanded by transporters Leased wagon - increases reliability on dispatches - lower transit time leading to reduction in inventory 6
DIRECT TO TRADE Direct to trade Immense SCM Opportunity.
Factory
Stock Pt
Dealer
Most suitable for Major Distributor supply who need Full Truck Loads. Reduces Inventory at W/H level. Reduces handling and operational cost. Improve quality of service and customer satisfaction.
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MULTIPOINT PICKING ~ DELIVERY Fact-3
Fact-2
Fact-1
Dealer
Dealer
Eliminate extra W/H requirement.
Fact
Reduce cost
Dealer
Faster Delivery Dealer Fact-1
Dealer-1
Fact-2
Dealer-2
Fact-3
Dealer-3
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MOVEMENT CONTROL ~ GPS Central Server
GPS signal to locate GSM sends location / speed info to Server
Internet Remote Assistance
Mobile Maps / Navigation
Asset with GPS Hardware
Diagnostics and Reports
Vehicle Owner / Consignor / Consignee 9
HUB-N-SPOKE NETWORK Features of a Hub-N-Spoke Network Decreased Inventory cost • Inventory pooling benefit - Reduction in safety stock due to better forecasting at the aggregate hub level • Inventory Postponement - If demand can be fulfilled from the hub within the given service time, then branch stock can be eliminated. This also results in reduced handling at the hub (since the material is only flowing-through the branch) Decreased Warehouse space cost • Due to the reduction in overall inventory there is a reduction in space requirement in the network Increased Handling cost • Product gets handled twice - once at the hub and once at the spoke Increased transportation cost • A single move from supplier to spoke is broken into two moves - supplier to hub and then from hub to spoke. This results in increased transportation cost. • A reduction in part of the transportation costs is possible if there is an opportunity to consolidate loads into hub
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HUB-N-SPOKE NETWORK Factors that drive a Hub-N-Spoke Network Value to Size ratio • A high value and small size product is likely to benefit from the hub-n-spoke structure. High value results in a higher savings in inventory costs whereas a low size results in a smaller increase in the logistics cost. Thus, on the whole there is a benefit. Service Times that allow postponement • Flexibility in service time allows demand fulfillment directly from the hub. This would drive large reduction in inventory by eliminating inventory at the spoke. • With stringent service times, the overall inventory levels do not reduce by much and sometimes can even increase in a hub-n-spoke network structure. Inventory Pooling • Demand variability may be lesser at the Hub compared to the spoke, as the variability at the spokes might offset each other. This would result in lower variability at the Hub. The higher the reduction in this demand variability at the Hub, the greater the inventory pooling benefit.
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NATURAL LIGHTING - GREEN WAREHOUSE
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TURBO VENTILATOR - GREEN WAREHOUSE
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5 S PRACTICES
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CHALLENGES IN CONSUMER DURABLES SUPPLY CHAIN
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SALES VOLUME ANNUAL 100000 90000 80000 70000 60000
week4 week3 week2 week1
50000 40000 30000 20000 10000 0 A
M
J
J
A
S
O
N
D
J
F
M 16
SALES VOLUME ( Apr to Mar )
60000 50000 week1 week2 week3 week4
40000 30000 20000 10000 week1
0 A M
J
J
A
S
O
N
D
J
F
M
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TOTAL FREIGHT COST MOVEMENT 500
60
460
50
41 420
37.57
40
30.00
27.88
GAP WIDENING
380
37.84
30
24.38 20.71
361
340
20
339
333
328
314
300 01-02
02-03
330
307 03-04
Total Freight / Unit
04-05
05-06
10 06-07
07-08
Average Diesel Price / Ltr
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TYPE OF VEHICLES USED
Containerized 65’ Trailer Used for Volumetric movement
Containerized 45’ Trailer Used for heavy movement
Double Axle Vehicle Used for weight movement upto 16 Tonnes
Containerized 30’ Vehicle Used for Combination of weight and volume
LCV for Secondary
9 Tonner Punjab Body Vehicle
For short route despatches
Used for movement by weight
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WAREHOUSING PRODUCTS RANGE
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PRODUCTS RANGE Multiflex – Light Duty Shelving X span – Long span shelving Mobile Shelving Pallet Racking Drive-In / Drive- Thru systems Gravity Flow Cantilever
Carton flow Cable Drum Storage Mezzanine Floors Library Stacks. Workshop Equipment Vertical Carousals Kardex Shuttle Automatic Storage and Retrieval Systems Consultnacy Special Solutions
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LIGHT DUTY SHELVING
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HEAVY DUTY SHELVING
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LIGHT DUTY MOBILE
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SELECTIVE PALLET RACKING
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DRIVE IN/THRU PALLET RACKING
DRIVE IN WITH PALLET
DRIVE IN WITH MHE
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DRIVE IN / GRAVITY FLOW
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MEZZANINE
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CARTON FLOW
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VERTICAL CAROUSEL/SHUTTLE
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WHAT IS AS/RS AUTOMATED STORAGE & RETRIEVAL SYSTEM IS A CUSTOMISED COMBINATION OF
GODREJ-EFACECAUTOMATION AUTOMATION&ROBOTICS LTD. WAREHOUSE AREHOUSEMANAGEMENTSOFTWARE.
DECserver Micro VAX
Micro VAX DECserver
Type text
Type text
Visolux
DECserver Visolux
PLC Modem
BarCode Stacker Crane
INTELLIGENT EQUIPMENT
HI- RISE STORAGE SYSTEM
WAREHOUSE MANAGEMENT SYSTEM 31
COMPARISON OF VARIOUS HANDLING EQUIPMENTS
The Stacker Crane meets all desirable features of an MHE – It goes tall , very narrow aisle, no deration, no turning, etc. 32
Thank You
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