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Otm 2013 c13_e-18a-sabharwal-naval-covert-waste-to-value-with-otm


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Otm 2013 c13_e-18a-sabharwal-naval-covert-waste-to-value-with-otm

  1. 1. Convert Waste into Value using OTM Value IN Waste OUT Get More form your OTM
  2. 2. Boxing BoutMr. TIMWOOD Mr. OTM
  3. 3. Who is Mr TIMWOOD? Inventory Transportation Motion Defects 7 Deadly Wastes Waiting Over Processing Over ProductionSTRATEGY :-Distracts you and attacks with• SHORT JABS• BACK HAND PUNCH• TWIST PUNCH
  4. 4. Mr TIMWOOD is all prevalentWaste What is it? ExamplesTransportation • Unnecessary transportation • Moving over longer distances than moves required.Inventory • Excess resources deployed • Under-utilised Vehicle / than required EquipmentMotion • Actions of people or • Manual Data Entry equipment that do not add • Misalignment of Dock scheduling value to the process with staging pointWaiting • Materials not moving • Order stuck in a queue • People waiting for work • Staging of packages • Vehicle waiting to be handled
  5. 5. Mr TIMWOOD is all prevalentWaste What is it? ExamplesOver-Production • Producing more than • Moving packages through express is actually required when normal mode can meet delivery dateOver-processing • Working beyond what • Adjustments of shipment units in a is needed to satisfy container the customer • Re-checks in process • Any unnecessary steps • Duplication of Data Entry in processingDefects • To work over again, to • Rework revise, to repeat a • Rejects process usually to correct an error
  7. 7. Plan before the Bout : Value Stream map : Logistics Operations ADC Manual Verbal Orders to suppliers Parts Kitting TMS Special dixs Customers CT: 18 mins ERP CT: xxxxx Outlets / Dist People 13 ERP Planning People xxxx Consignment Shifts : 2 Shifts : 2 Freq: daily 25/30 Load : 5000 Mtrs ps ERP Load : xxxxx Total qty items: ERP NA Discrepancy ERP ERP report Daily Non Invoice + LR availability TMS TMS Goods Sorting and Packing Weighing Binning Zone wise Scanning Consolidation Receipt Merging Staging CT: 5 mins CT: 12 mins CT : 16 mins: CT: 6 mins CT: 2 mins CT: 2 mins CT: 2 mins CT: 8 mins People: 1/2 People: 1/6 People: : 1/20 People 1/4 People People 2/4 People:: 2/2 People 3/12 Batch size -SKU Batch size-SKU Batch :-86 mtrs Batch – 86 mts Batch – Pick list Batch – Ship Unit Batch – Ship Unit Load :- 40000 Load :- 40000 Load40000 Shifts 2, Load : 200 pd Load4 0000 Load – 1000 Load – 1000 Mtrs per day Mtrs per day Mtrs pd mtrs pd : : Bales pd Bales pdNVA 45 mins 24 mins .45-60 days 60 mins .32 mins 25 mins .20 mins 45 minsVA 5 mins 12 mins 2 mins 16 mins 6 mins 8 mins 2 mins 2 mins TIM WOOD had created 82% waste in the operations
  8. 8. TIMWOOD had attacked multiple areas Waste Waste IdentifiedTransportation • Multiple vehicles routed to same region on same day • Last minute changes in plans necessitated by business was leading to excess transportation movesInventory • Vehicle capacity was not effectively utilisedMotion • Repetitive Manual planning entry was slow , errors and unproductiveWaiting • Manual Dock scheduling resulted in wait time & demurrageOver • Ordering excess capacity due to lack of visibilityProductionOver Process • Manual Invoicing by carriers led delayed payments & leakages • Ship Unit re-loading, adjustments after loading a container to optimise space utilisationDefect • Transhipments of critical items led to product damages • Fitment Parts were left out while the main assembly was shipped
  9. 9. Let the match beginMr. OTM Mr. TIMWOOD BOX
  10. 10. Removing the “Inventory” Waste by using container space optimally• In “ Load Configuration” Configure “custom” logic configuration with type “Container optimization” – Parameter Value “ TRUE” for the Parameter USE 3D BASED LOAD CONFIGURATION• Install Cortona 3D viewer• Configure new parameter set – Set the Parameter Value “CONTAINER_OPTIMIZATION” for the Parameter CONTAINER OPT CONFIG ID – Priority Setting was selected as “Yes” to enable critical items to be dispatched first – Stackability Norms were build at the Ship Unit specification level
  11. 11. Removing the “Inventory” Waste by usingcontainer space optimally : 3D Output
  12. 12. Removing the “Inventory” Waste by usingcontainer space optimally : Handlers Output
  13. 13. Removing the “Inventory” Waste by usingcontainer space optimally : Loading Pattern To arrive at the ideal loading pattern multiple “waste identification exercises were undertaken” and best loading pattern was determined based on which • Load Configuration was configured and Pinwheel Loading pattern* was set up at ship unit • Maximum Number of Stacking Layers were set up • Maximum Number of Loading Rows were set up Notes If the Maximum Number of Stacking Layers or Maximum Number of Loading Rows is left Crosswise Standing Straight blank, then no restrictions apply. Loading Patterns* specify the orientation and layout for when ship units are loaded in Standing Nested Lengthwise equipment. Canon Rolling
  14. 14. Removing the “Inventory” Waste by usingcontainer space optimally : Tim Wood has a Black Eye
  15. 15. Removing the “Inventory” Waste by usingcontainer space optimally : Future Proofing• Due to changing Business needs we understood that Loading Configuration and Loading Patterns may not provide optimized results for the future too• A What if Option was created to review outputs with different loading patterns wherein the weight / volume utilization was less than 95%• Operations staff can re-set the Loading Patterns for Group of ship unit based on trends established through the What If scenario
  16. 16. Removing the “Defect” Waste of Fitment Parts leftout while the main assembly was shipped using BOM StructureFitment parts and Main Assembly are identified• In “ Item” Configure new BOM Structure – Enter details of fitment parts – Establish link to Parent ( Main Assembly) – Create new planning group “SHIP TOGETHER”. – Planning group for all the parent and child item is managed through an agent which automates the check as an mandatory option. – Plan orders with the agent Planning group.Notes : This can be done at item level and need notbe repeated again and again. The BOM data can bepulled in from BOM data maintained in your ERP• Any attempt to ship the parent without the child throws up an error for the parent to be dispatched Left Hook : TIMWOOD is Wobbling
  17. 17. Removing the “Transportation” Waste to cater to lastminute changes in plans : Using the Re-Sequence Option Load is planned for multi stops and load is tendered to the carrier and needs re-sequence of stops • In “ Buy Shipment / Action” select option Re- sequence stops • Change the sequence numbers and save. Lane based option was used • Carrier will also be apprised of the sequence change • Cost and service level impact due to the sequence is also visible before a decision is taken • Incase carrier has been secured the re- sequencing option can still be used. • Carrier apprised of the sequence change and the resource secured is marked as “un-scheduled” till the carrier accepts the change Notes • Incase carrier has executed the load the re- sequencing option can still be used. • Carrier and Driver apprised of the sequence change through mail and VTSTIMWOOD rises after a 3 count
  18. 18. Removing “Transportation” Waste of Multiple vehiclesrouted to same region on same day by using pooling OptionMultiple Points are clubbed into a region and transithubs are also entered in the master data• In “Iternary” configure source the deconsolidation pool point and destination.• When you plan an order it consolidates orders together for the region for the consolidation pool point.• The consolidated load is used to identify the best equipment• LTL shipments are created from the deconsolidation hub to the respective destinations• Cost for direct and pooled delivery are visible before the final option is exercised Here comes the Upper cut TIMWOOD being treated for Cuts
  19. 19. Removing “Over Process” Waste of Data Entry ofManual Invoices by using conversion and loading tools Manual / PDF / Excel format XML formatProcess Scanned Invoices Invoices Invoices Received received received Invoice Manual Manual ( Excel ) RegistrationInvoice and POD Manual Upload Data Upload Data Entry OTM OTM OTM Verification • High Manpower Cost • Data Upload Errors • Inaccuracy • Mapping Errors • Training • Infrastructure Cost
  20. 20. Removing “Over Process” Waste of Data Entry ofManual Invoices by using conversion and loading tools Manual / PDF / Excel format XML formatProcess Scanned Invoices Invoices Invoices Received received received Invoice Scan Excel to XML Registration converterInvoice and POD Digitize, Map & Map & Load Map & Load Data Entry Load OTM OTM OTM Verification
  21. 21. Removing “Over Process” Waste of Data Entry ofManual Invoices by using conversion and loading tools Fetch Map Web-service Digitize Load XML iFetch iCap LoadX OTM • FTP based fetch • Digitize correct • Mapping Accuracy • Freight Settlement • OCR convert If required • Loading accuracy • Inbuilt intelligence • Error window TIMWOOD send back to the Corner before round ends
  22. 22. Removing “Defect” and “Wait” Waste leading to damages and demurrage charges by using Mobile solsEquipment# / LR# and Vehicle# on departure from theplant are transmitted to a Mobile App at the receiving site – On receipt of vehicle the gate selects the Equipment # / LR # – The App pops up a list of Vehicle # and selects “Vehicle does not exists” – Receiving person selects the vehicle number or “Vehicle does not exists” option. – Incase “Vehicle does not exists” is selected the App requests the receiving person to take an image• The receiving date and time are also used for settlement of the bills and monitor service levels – Shortages and Damages if any are also captured with images in the Mobile App at the point of unloading• The time difference between the receiving date and time and the actual unloading is used to calculate the demurrage charges. Hook Punch TIMWOOD is on Count of 10
  23. 23. Removing “Defect” and “Wait” Waste leading to damages and demurrage charges by using Mobile sols Web Service Map Web-service Load OTM POD App LoadX OTM• Despatch Data • Transshipment • Mapping Accuracy • Freight Settlement Transfer Integrity • Loading accuracy • Shortage / damage • Error window Integrity • Arrival times • Demurrage Management App Technology Elements Hardware Android/iOS Device with a device camera for scanning barcodes Software RedLaser SDK (licensed) Or ZXing SDK for Android Devices 2.2+ required to provide Process Flow Bar Code scan functionality The data and business logic present in the OTM server is exposed to the mobile client using OTM web services. The mobile App accesses these web services over http/https to acquire/update data TIMWOOD is on Count of 10
  24. 24. KNOCK OUT Waste Out Value InMr. TIMWOOD Mr. OTM
  25. 25. NEED HELP TO KOCK OUT MR. TIMWOOD CONTACT US contact no +44 contact +49 contact no +91 9004014283 Visit us at Our OTM Lab at Chennai, India