2. High plant
turnaround
times
(GIGO)
High yard
waiting time
Safety issues
within the
plant
Efficiency at
Packer
(Productivity)
MIS to track
different
KPIs
High
dependency
on people
Long &
variable
transit times
Operational Challenges at Plant Site
3. What is THE Business Goal?
Primary
Tracking the KPIs with regards to Inbound / Outbound process
management to improve productivity / plant process efficiency
Implementing Controls and Checks around Logistics Operations
Weigh Bridge Automation / integration to reduce Theft and Plant
in-time for vehicles
Run Time Production counting for Outbound Process
Improve the Packer efficiency
Automatic MRP Printing on Bags to remove manual errors
Controlling Busted g Bags and Increase Plant ‘s Dispatch
Secondary
Minimize paperwork and dependency on people
Improve plant safety
Improve service level to customers
4. What Needs To Be Done
Process Improvement
Security
Entry
Process
Delivery
Order
Process
Weigh-
bridge
Process
Bag
Counting
Process
Bag
Printing
Process
Integration – Industrial Process + Application
5. Reduced
Vehicles TAT
•Reduce TAT Inside the Plant
•Reduce Yard Waiting Time
•Reduce Plant Waiting Time
Improve Plant
Safety
•Control Movement of Vehicles within Plant
•Minimize People Dependency and Paper Transactions
Automation
& Productivity
•Align Dispatches with Order Requirements
•Sequence Entry of Vehicles into Plant
•RFID Based Tracking of Vehicles
•Automation at Packer, Weigh Bride, Loading Points & Gates
• Improved MIS
Benefits
6. Amazin Solution - PLMS
Gate –In Stage
Yard Stage
Weighbridge Stages
Higher safety
and Less
Dependency on
Human
Can be easily
integrated with ERP
Low Yard Time
Low TAT
Higher Loading utilization
Control & analytics
Automatic DO and
IGP is Created as
soon as vehicle
enters into yard
More Visibility
over vehicles at
yard and Plant.
Sequencing is done based on
Vehicle arrival timing in Yard &
Product type
Alerts and reports for
Unauthorized Vehicles
7. Components of Proposed Solution
Hardware Layer
UHF RFID readers and tags, GPS, LED display, Signaling systems, boom barriers &
PA system
Middleware
• Integration with packer & bulk loader PLC.
• Integration with weighbridge, bag / bottle / boxes counters, MRP printers etc.
• Integration with ERP (SAP) and other transaction systems
Transaction system
Yard, weighbridge, gate, loading & unloading
point transaction, Production Counting, MRP
Printing recording
Analytics
Real time analysis
and Dashboards
Reporting
User defined
Management and
Operational Reports
Optimization
layer
Fleet scheduling
and queuing logic
Collaboration
layer
Transporter
collaboration and
reporting
Extension framework
User defined stages, events and
alerts to address specific needs
8. What Will This Do ?
■ Real time control and visibility into all major activities within the plant
■ Sophisticated scheduling ensures best possible schedule for trucks and
packers
■ Scheduling generated the truck entry sequence
■ Queuing ensures trucks enter as per plan
■ Immediate re-plan whenever something goes wrong
■ Give visibility to drivers and transporters on upcoming requirements
Helps the larger community
■ Synchronized movement will lead to lower lost time, lower logistics cost
and higher service level
■ Planning of operations
■ Move beyond simple automation to a more proactive approach
9. How This Will Help ?
■ In plant turnaround time will be decreased 30-90 mins
■ Average yard waiting time will be decreased 2-3 hours
■ Loading utilization will be above 90-95%
■ Customer service (on time delivery) of 80-90%
■ No manual Entry Gate Check-In
■ LED Displays at weighbridge, loader and yard to guide the drivers
without human intervention
■ Packer and CDS dashboard will show the continuous progress of
loading statistics
■ Reduce accidents in the plant
■ Fewer manpower requirements for supervision, communication etc.
10. Business Benefits
■ Increase the no of Trips by 20-25%
■ Reduced Yard detention and In-plant TAT by 4 - 5hrs (500 trucks/day
saving is 2000 to 2500hrs
■ More ROI for transporters (30%)and bargaining power for the plant
management.
■ Dispatches can be managed with reduced fleet – Reduced logistics
costs.
■ Minimal man power needs and elimination of unnecessary paper
transactions –entire dispatch system is automated from – yard in to
plant out.
■ Packer optimization to increase productivity throughput.
■ Enhanced customer satisfaction.
11. Sample Business Case
Activity Before
Solution
After
Solution
(estimated )
Benefit
1 In plant TAT 2-3hrs 1hr Saving of
1hr
2 Yard Detentions 5-6hrs 2-2.5hr Saving of 3-
4hrs
3 Total Time savings 4-5hrs
4 Plant out to (cust) to
Yard In
12hrs
(assumed)
5 % of dispatches
increased by
20-25%
