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Showing posts with label Warehousing. Show all posts
Showing posts with label Warehousing. Show all posts

Six Sigma Methodology

October 27, 2020

Six Sigma Methodology 

Six Sigma Methodology

Six Sigma has two methods DMAIC and DMADV, each with its own set of recommended procedures to be implemented for business transformation.
Six Sigma uses two different sets of methodology as lenses to examine and address complementary aspects of business processes.
Each method has its own data and tools, through which it can be used to improve business processes.

What is DMAIC? 

DMAIC is a data-driven approach that is used to improve existing customers or services, and also to improve customer satisfaction. DMAIC is used in a product manufacturing organization or any service delivery company.

 DMAIC has five steps

D - Define

M-take measures

A -Analyze

I - improve

C -control

What is DMADV?

DMADV is a part of Six Sigma design, DMADV is used to redesign the processes of product manufacturer or service delivery. 

Remember DMADV is employed when existing processes do not meet customer requirements, meaning DMADV is used to replace your existing processes, or even if your product or project needs to be developed DMADV Is required.

DMADV has five steps:




D- Design


Difference Between DMAIC and DMADV

DMAIC is used, or will be, when you are trying to improve or develop a process that already exists, meaning your product or If there is a need to improve or develop a little project.

DMADV is used when redesign is to redesign your product or project. By the way, the purpose of both the methods is the same, to solve the problem of your business in a complete way. 


The six Sigma process begins with a customer-centric approach.

stage 1: Business problem is defined from the customer's point of view.
stage 2: The target has been set. What do you want to achieve What resources will you use to achieve the goal?

stage 3: map the process. Together with stakeholders verify whether you are on the right track.


MEASURE- In this, you need the data of the instruments used to make measurements, and also need to know the answers to some questions. How can we improve? How can we determine this?
stage 1: Measure your problem data with data on how to improve.
stage 2: Evaluate the data system to be improved, then you will know whether it can help you achieve your result or not?


This is the process to find the affected Variable, which enables us to analyze.
stage1: 100 percent Determine if your process is efficient and effective, can the process help you achieve what you want?

stage 2: Set your goals. For example, reduce defective items by 20%.

stage 3: Identify differences using your old data.


This process examines how the effect of your old data changes to the new data, this stage is where you identify how you can improve the process by implementing it.

Stage 1: identify possible causes.
Stage 2: Discover the relationship between Variable.


In this final stage, you determine whether the performance and purpose identified in the previous stage are implemented well, and whether the designed improvements are sustainable.

stage 1:
Validate the measurement system used.

stage 2: establish process capability. Whether the goal is being met or not? For example, is the goal of reducing defective items up to 20 percent achievable?

stage 3: Once the previous stage is satisfied, implement the process.

Six sigma technique 

The Six sigma method also uses a mixture of Proven qualification and quantitative techniques to achieve desired results.

A : Brainstorming 
B : Root cause analysis
C : Voice of the customer
D: The 5s system
E: Kaizen
F: Benchmarking
G: Poka -Yoka / Mistake proofing
H: Value Strem Maping


Brainstorming is an important process of any problem solving method and is often used in the "improvement" phase of the DMAIC method.

Before starting any tool, it must be a necessary process. Create a group and brainstorm and sit with everyone and creatively raise the problem and then implement it.

Root Cause Analysis/The 5 Whys 

This technique helps to get to the root of the problems under consideration, and is used in the "analysis" phase of the DMAIC cycle.

5 Why 

5why In this technique, the question of "why" is asked repeatedly, eventually leading to the main issue. Although "five" is a rule of thumb, the actual number of questions can be more or less, whatever it takes to get clarity.

Voice of the Customer 

It is a process used to capture the "voice of the customer" or the customer's response through internal or external means. The aim of technology is to provide the best products and services to the customer.

It captures the changing needs of the customer in direct and indirect ways. The voice of the customer technique is used in the "Defined" phase, usually to address the problem.

The 5S System 

The purpose of the 5S system is to remove waste and remove obstacles from unskilled equipment, equipment, or resources in the workplace. The five stages used are ciri (sort), citan (set in order), ciso (shine), csetsu (standardized), and shitsuke (susten). The 5S system will be known to many of you and we have also written a blog.

Kaizen (Continuous Improvement) 

Kaizen technology is a powerful strategy, which powers a continuous engine to improve business. It makes it a practice to continuously monitor, identify and implement reforms.

This is a particularly useful practice for the manufacturing sector. Ensures collective and ongoing improvement, and helps make immediate changes.

Poka-yoke (Mistake Proofing) 

The name of this technique comes from Japanese phrases, meaning "to avoid errors," and prevents the possibility of mistakes being made.
In the poka-yoke technique, employees overcome disabilities and human errors during the manufacturing process.

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What is a Store?

October 26, 2020

What is a Store?

What is a Store?

The definition of Store for different Business may be different, and its responsibilities can be according to store and product. But here we are talking about the supply chain Stores:

 Store is a place where additional goods are kept, which can be used when needed. And items are also stored in case of problems, such as: Damage, Wrong received, Discrepancy etc. All these are also a part of the store.

Store management "takes care of proper and improper materials when receiving materials, such as: Damage, Wrong, rusty Etc. and works immediately to protect them in the Store, and choosing the right materials and the right place to place them in the right quantity. And that too at a low cost, store management is also responsible for all this.

Purpose of the store In the chain of internal customers and chain of suppliers, the store has many internal customers. Customers are expected to deliver good quality and low-cost delivery from every Suppliers as usual.

The store also has to fulfill its customer's expectations. All of these are activities with responsibility and process that people carry out in the work of the Store.

The aim of the store is to minimize the cost on objective materials, thereby reducing the cost of production.

Maintaining a reasonable price for content so that user departments can get good service. The store does the major work of establishing good coordination with all other departments. In the next blog we'll talk more on this, Thanks 

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Warehouse Equipment

October 24, 2020

Warehouse Equipment

Warehouse Equipment

Warehouse Equipment - No matter how good manpower you may have to streamline your warehouse operations, it is the equipment itself that plays a very important role in helping humans to complete a task efficiently.

The processes and approaches done inside the warehouse give results for your business. This is the same principle not only in the warehouse but also for every business in the world.

If we list the equipment and machinery used in warehouses, then we will be very long but we have taken broadly, which we need more.
Even today many warehouses or businesses are unaware of the methods and equipment they need. To increase the speed and efficiency and productivity of materials management in any warehouse or business, then you should have proper equipment.

Many challenges are being seen in the modern warehouse. Such challenges not only affect the running of the warehouse, but also negatively affect production and distribution, if you do not have the appropriate equipment.

Getting or keeping the right equipment for the warehouse will not only reduce the flow of goods through each process area, but will also reduce the possibility of injuries and product damage.

The material handling equipment must conform to the size of the facility warehouse and material. Make sure what equipment is really needed in your warehouse or business.

We will discuss some special and very important equipment of the warehouse so that you do not have any kind of rage, you can see it according to your needs.

Warehouse Material handling equipment

Choosing the wrong equipment can put employees at risk. Therefore its safety should always be your top priority. If you want to optimize your equipment area and workflow, you need quality warehouse equipment to move equipment and cargo.

Warehouse security is also becoming a major issue, choosing the right equipment can make your process more efficient, customizable and qualified and secure, as well as less time consuming for workers. Let us know about the material handling equipment.

1. HPT- Hand pallet Truck- One of the most used equipment in any industry includes - Hand pallet truck - This allows you to easily move small and large cargo from one place to another. As effective methods of handling various heavy objects, they are used:

2. Battery stacker - used to hold items at a height, it is a battery operated device. It is used for heavy duty racking system

3. Forklifts - There are very few people who would not know forklifts, which is also a tool used in almost all types of warehouses like HPT. Forklifts come in many sizes such as: high capacity, weight capacity etc.
However large warehouse corridors are required to bend forklifts.

4. Reach trucks - are the most common equipment used in large warehouses and in heavy duty racking system wall racks, mainly because they have the advantage of working in narrow streets and elevations of up to 14 meters in height. Reach trucks are battery-electric equipment.
Reach trucks include features such as turret trucks, side loaders, order pickers, cranes, and pallet jacks. It is important that you find the best truck to suit your needs.

5. Hydra crane- is used in handling huge and heavy materials. Hydra machines can carry and carry loads of almost any material used in a warehouse.

Peaking Packing Equipment - Packing equipment is very important for any warehouse, peaking packing equipment plays an important role in packing shipping goods faster and helping to increase productivity.

The right packing equipment can reduce labor costs, and provide stability in the process. In addition, packing equipment also improves inventory control by eliminating the possibility of product isolation, saving time in inventory count.

Warehouse Picking Packing Equipment:

BOPT-battery operated pallet truck - is included for loading / unloading and order picking. And they are easy to use, and they are also very fast and powerful. This allows the material to be transported and transported very fast, and can be used by any person, increasing the efficiency of peaking.

Apart from this, some equipment used in peaking packing is given below which is important.
for example :

1. Industrial scales
2. Strapping and banding equipment
3. Stretch Wrap Machines
4. Sealing machine or band sealer machine


As you know, it is important to have equipment in the warehouse, but it is more important that you are handling it, and how much you are looking after it, before and after you buy the equipment. In this, information should be collected, why the equipment is needed, who will handle the equipment, the correct parking place for the equipment is also necessary. How much profit our business is going to make. Many tools have been left in this blog, you will talk about it further. 

Thank you - and my blog is becoming useful for you, so please tell us by commenting.

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Business Solution 

Distribution center vs Warehouse

October 23, 2020

Distribution center vs Warehouse


Distribution center vs Warehouse

Some people want to understand the difference between its Warehouse and Distribution center because of its confusion. These both work for the supply chain and what the supply chain wants is to deliver the right goods, the right price, at the right place and at the right time.

Due to the similar appearance of warehouses and distribution centers, many people will not be clear about the difference between them, and even in the logistics industry the two will not be different for anyone. Even till a few months ago, we also thought that this name is two, but there is no difference between them. 

Then I got to know about it and we reached a distribution center and then I came to know that there is a lot of difference between the warehouse and the distribution center, even though they look the same from outside, but there is a lot of difference in internal work. There are responsibilities to complete each work which is made up of different technical and criteria.

As many of you would be aware that the already existing traditional warehouses are no longer able to meet the supply chain demand. However, many warehouses are being upgraded.

Let us know what is the difference between a distribution center and a warehouse

Typically, warehouses are used to store goods, while many additional services are provided from distribution centers such as: order fulfillment, cross-docking, etc. Distribution center products typically have a much faster expiration period than warehouse. Basically, the process speed of the distribution center works faster in a manifold than in a warehouse.

The main function of a warehouse is to store goods efficiently
, while the main function of a distribution center is to meet customer demands. Typically, orders from warehouses and retail are sent by distribution centers, not from the main warehouse. Again, the warehouse usually does not accept external customers, while the distribution center accepts orders from external customers.

The distribution center mechanism is more complex than that of a warehouse in general. Therefore, the distribution center is equipped with the latest technology to manage the ordering process, warehouse management, transportation management and others.

There are differences between a warehouse and a distribution center and distribution centers keep updating over time. However, if you say that the warehouse is no longer needed, then you are completely wrong. There will be a need for a warehouse, such as seasonal products and according to seasonal demand you will need to stock your items.

There is a clear distinction between a warehouse and a distribution center. If you want to build a warehouse or distribution center, it is a good idea to build it in a strategic industrial area. Let's understand this in a little detail

What is a warehouse?

By the way, you must know what a warehouse is, and we have given many blogs about it, but to understand its difference, let us look at it once more. "Warehouse is a commercial building which means a big building Which are used to hold goods, and warehouse to store and handle goods properly using warehouse scientific methods. They are mainly used by manufacturers, importers, exporters, wholesalers and transportation businesses. Let's go. Warehouses are usually used for storage only.

The warehouse has a loading dock for loading and unloading goods, that is, you can run the warehouse with very little equipment. Warehouse can be anywhere and it should be on the side of the buster road.

What is a distribution center?

A distribution center is a special building designed to store products for everything from retailers to wholesalers, which can be distributed elsewhere or directly to customers. Meaning you can buy goods online or offline from here.

Distribution centers are an integral par
t of the order fulfillment process, especially for online retailers and e-commerce businesses. The normal route of transportation is usually as follows: a retailer sends the product to a distribution center, and then the product is shipped to the consumer customer. 

Because the products move in and out at high speeds, distribution centers are often located in areas where transport facilities are available, such as near major roadways and highways to more efficiently transport and move goods. Many distribution centers are part of a larger network of distributors, set up to serve a larger area.


A warehouse is a storage facility intended to store goods for a long period of time, if compared briefly. And a distribution center is in the form of a warehouse with full fulfillment services and many other benefits. 
In a technology era that is impacting every aspect of normal life, online shopping is creating demand for accessibility and speedy delivery to sustain businesses - such as: 2-day shipping from Amazon or Flipkart Can see Businesses that get their products faster and have streamlined their supply chain management.  

Unlike warehouses, distribution centers are multifunctional, high-energy operations that provide fulfillment services, although the way to obtain those services varies from building construction. Because of that, they are sometimes called "fulfillment stores". They double as a warehouse or can be a warehouse component, although they easily combine with a separate warehouse if they do not have that capability. 

Stocks are placed according to demand in the distribution centers and those goods are shipped elsewhere when the demand is out, in the distribution centers things always work very fast inside a place such as when an order is placed The latter is how businesses can be offered quicker shipping, which also has a hand in improving customer satisfaction and recognition. 

Warehouse's distribution centers are equipped with an abundance of storage technology. For the most part, the system of operation of a distribution center is virtually paperless, as everything can be obtained digitally with the help of computer and handheld technology. Reducing paper records not only accelerates the filing process, but also the amount of space previously required to store boxes of paper records that the company needed to keep. Some distribution centers have more automation than others, and use technology such as conveyor belts, automatic sorting, weighing, and even self-operating ankle boarding. 

Distribution centers also allow greater tracking and transport transparency to the customer and business owner to provide better customer service. Such as: With the use of radio-frequency identification (RFID), GPS, Universal Freight Operating System (UFOS), other technologies or some combination of them, companies are able to track products with great accuracy. Customers and business owners can view their products from the moment they leave the manufacturing plant to successful delivery to the final owner of the product.  

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Warehouse outbound process flow

October 21, 2020

Warehouse outbound process flow 

Warehouse outbound process flow

The Warehouse Outbound Process is initiated under a systematic operation procedure with documents and planning, so that any Material going out of the warehouse can be transferred or sent to the Customer and vendor, and can be easily Managed .

The Outbound process involves a lot of process and there are different complexities in performing these activities. But if the outbound process flow of your warehouse is good then you will be able to manage it easily.

The outbound process in the warehouse consists of the following process with the following document, which you will know step by step here.

Sales-Incharge > Production planning > Step-01 

1. Download Customer order or delivery number in excel sheet from SAP 

2. Distribute customer orders into 3 parts on priority, such as urgent, SALES and stock transfer orders. 

3. Prepare the picklist and picklist. This department has to be managed very smartly because it requires speed and efficiency. 

Picking strategies allow warehouses to better select products for the type and quantity of orders they process. Here are some examples of choosing a strategy: 

Zone picking -Peaks are divided into zones wise in the warehouse, they are responsible for peaking the area in time. If there are many items in a single order for several zones, then that order will go to different zones and done by many pickers. 

Batch picking - Selects all orders for a batch at the same time. In this, the quantity of material of all the orders is picked together, and while packing it is distributed on the basis of customer, this is usually done when it is to be packed. 

Batch picking reduces travel time within a warehouse, which is according to the supply chain. 

4. Print the pick list and pack list and summary sheet 

4. Hand over the pick list to picking supervisor and take the acknowledgement on summary sheet. 

Picker > picking > Step-02 

1. Picklist collects from supervisor and segregate zone or location wise 

2. Supervisor Update Picklist in Control Register and distribute Picklist to Picker 

3. Go to locations with Picking trolley in location sequence as per Pick List 

4. Match Material code in picklist with part in bin location .If not found item in bin location then inform to supervisor to resolve. If yes pick the required Qty. 

5. Enter picking end time in control register 

6. Handover picked materials to Packing section along with pack list 

Packer > Packing > Step-03 

Start packing More focus on QUALITY packing and Start packing and follow the Fourteen "R" Packing rules and sequence

1. Right Pack list: have taken the right picked material and pack list? 

2. Right Part: are you packing the right PART number? 

3. Right Quality: are you packing the good quality part? 

4. Right description: have you checked the description? 

5. Right MOQ: are you packing the right Material order quantity? 

6. Right Quantity: have you checked that you packed the right Quantity? 

7. Right carton: have you used right cartons/consumables in packing? 

8. Right MRP: have you checked that right MRP is affixed? 

9. Right coupon: Have you checked that right coupon is affixed if coupon applicable? 

10. Right marking: have you done the right marking? 

11. Right Filler Material: - Have you used the right filler material and good packing? 

12. Right Case Tag: have you generated and affixed the right case tag on box? 

13. Right Weight: Have you weighed and written the weight on the right box? 

14. Right strapping: have you strapped the box correctly? Do the amendment in pack l ist in any. Scan the pack list for completion. 

Sales Supervisor > planning and invoicing -Step-04 

Production planning and execution 

1. Now sales supervisor will collect the pack list with materials boxes from packing section. 

2. Check with the summary that was given during issuing the pick list to 
packing section. 

3. If not then recheck with packing section and get left any pack list with them. 

4. If there is any dynamic error during PGI (Post goods issue) then follow-up with field and HO. 

5. Now do the invoicing. 

6. Get the invoice printing. 

7. Get the printed invoice signed from authorized person 

8. For dispatch, put all documents in an envelope and allow to dispatch. 

9. file the documents in box file 

10. Permit generate or Apply if applicable 

Dispatch Supervisor > consolidation> Step-05

1. Packed box to be moved in consolidation area or HD rack zone. 

2. Write the Heavy-Duty rack location number on pack list where package material is moved in. 

3. Scan the pack list and download the location and mover name in file

Dispatch Supervisor > Dispatch > Step-06 

Dispatch planning, preparation and FINAL dispatch 

1. Prepared production plan as per SAP system. 

2. Print the ready to dispatch PLAN. 

3. Prepare LOADING sheet . 

4. Hand over the forwarding note and documents to consolidation area - floor staff 

5. Floor staff will pick the case from consolidation area and move to Pre-dispatch area. 

6.Hand over the documents and packed boxes to transporters ( Forwarding note, road permit if   applicable, pack statement , invoice. Dispatch incharge ensures that all boxes handed over to   transporter are properly packed , strapped , weighted , no damaged box given . 

7.Take the acknowledgement on forwarding note with al l documents from transporters. 

8. Transporter checks the boxes as per case no mentioned in forwarding note and AFFIX the transporter docket stickers on each box 

9. Transporter makes the GC and mentioned the details on it Permit no , permit expiry date, customer name , customer full address, destination , state document 

Supervisor >Dispatch > Step-07 

Dispatch planning, preparation and FINAL dispatch, documents filing. 

1. Prepared the loading sheet 

2. Loading supervisor will check each case number as per loading sheet while transporter loading the vehicle and Get the sign from transporter and security guard and self signature also. 

DEO>Dispatch >Step-08 

Shipment creating and complete  
collect the complete set of documents from transporter and Check the all documents with forwarding note and complete the shipment process in System in SAP. 

Here we talked about the warehouse outbound working process.
There are many points that we have to skip like this: Order processing, ordering etc. Because all this was not possible in a blog. But we will cover it one by one in the next blog.

If you want any help related to warehouse process or system or you have any suggestions, you can email us. Thank you !

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