We have 4-5 Dispatch Storage Area (DSA) of 100 mtr by 50 mtr, aprox 500-2000mtrs away from each other.
From the Production Bay (PB) the Finished Goods (FG) are transferred to DSA. Each FG has usable parameters viz. an Identification Number (UID), Quality Indicators (QINDs) and Weight (WTG). The FGs are arranged in DSA with help of Fork Lifts in a defined and orderly manner in specified zones. The DSA is demarcated into physical smaller grids/zones of 5 X 5 mtr in a physical manner with markers placed on the periphery of DSA.
n.b. – Each FG weighs approx. 980kg +/- 0-30kg.
Each TRUCK is to be loaded with approx. 9-10T of FG as per LS.
A. From the PB area the FGs are shifted by the Operator to DSA and are arranged at specific physical Grid Locations with help of Fork Lifts.
B. At the day end, Dispatch Plan is prepared for next day and truck placement request is sent to FG picker and Transporter.
C. The Picker identifies the require material at DSA as per the Dispatch plan.
D. The truck enters the plant and tare weight (TW) is recorded, QIND, Total Quantity to be Dispatched (TQTY), Truck Number (TN) is recorded on the Loading Slip (LS) before being directed to DSA.
E. With given LS (UID, TN, QIND and TQTY) the Fork Lift operator locate, reach, pick and loads the material identified by picker on to the truck.
F. The Loading Slip (LS) is completed recording specific FG UIDs and the truck moves towards the weighbridge for final weighment and then proceeds to the DISPATCH section for billing.
Placement of FG in the specified ZONE in DSA while receiving from PB is very difficult …..
During shifting of FGs from PB to DSA, the physical storage Location is not digitally linked on Database to the UID of FG causing problem locating in a later time while tracing for loading on to a truck.
Locating the FG in DSA leading to higher TURN AROUND time …..
At times due to some local problem of space, non-adherence to set procedure, unloading from a Consigner Truck, rearrangement of FGs within DSA, etc. the FG gets mis-located within the DSA and are difficult to locate, reach, pick and load the FG in a timely and efficient manner while loading the consigner truck.
Manual LS preparation and multiple point of data entry ……
The Loading Slip (LS) details are recorded on a paper and sent to Invoicing team for processing.
Defining a proper zone and storage of FG for ease of accessibility …..
To devise a procedure that is automated, smart and intelligent to bring in Quicker turn-around time of Truck Loading
a. Assistance to the process of Shifting FGs to DSA from PB
b. Tag the FG with GRID Identity to facilitate the Dispatch Process
c. Suggest Fork Lift Operator the next FG to pick
d. Option with Fork Lift Operator to look out for an alternate FG
e. Provide/Display a FG map overlaying the GRID of DSA
Problem Statement Type
30th October , 2018
30th October , 2018
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Problem Statement Creater College Faculty SPOC Students Team Leader