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S.No. Customer WI. VersiWI.

Versi Department
1 Celio 1.4 Celio1.4 Inbound
2 Celio 1.4 Celio1.4 Inbound

3 Celio 1.4 Celio1.4 Inbound


4 Celio 1.4 Celio1.4 Inbound
5 Celio 1.3 Celio1.3 Outbound
1.3 Celio1.3 Outbound
6 Celio

1.3 Celio1.3 Outbound


7 Celio

1.3 Celio1.3 Outbound


8 Celio

9 Celio 1.3 Celio1.3 Outbound


10 Celio 1.3 Celio1.3 Outbound
11 Celio 1.3 Celio1.3 Cycle Count
12 Celio 1.4 Celio1.4 Return Inbound
13 Celio 1.4 Celio1.4 Return Inbound
14 Celio 1.4 Celio1.4 Return Inbound

1.4 Celio1.4 Return Inbound


15 Celio
16 Celio 1.3 Celio1.3 Return Outbound
17 Celio 1.3 Celio1.3 Return Outbound

1.3 Celio1.3 Return Outbound


18 Celio
1.3 Celio1.3 Return Outbound
19 Celio

1.3 Celio1.3 Return Outbound


20 Celio
1.3 Celio1.3 Return Outbound
21 Celio
Process Workload Driver
Inbound Document verified with Pre-alert. No of Invoice
Unloading_ vehicle No of Boxes
Shipment Inward ( New ERP System ) No of Invoice
Physical Put away Process. No of Boxes
Pick list Generation in the Celio System No Of order

Picking Materials from Rack No of Pieces

Scanning Pieces No of
Pieces/Boxess

Packing of Material
No of Boxes
Shipment Outward ( invoicing in the Celio System ) No of order
Dispatch Document Preparation No of Docket
Cycle Count No of Location
Pre-Alert received from Celio Team No of Pieces
Unloading Vehicle of Return Material No of Boxes
Return Inward Shipment inward in new ERP System No of Invoice

Put away movement in the location


No of Boxes
Return Materiel Pick list Generation in the Celio System No Of order
Picking Materials from Rack No of Pieces

Return order Scanning in the WMS


No of Pieces
Return Material Packing for Dispatch No of Boxes

Return Shipment Outward (invoicing the Celio System)


No of Boxes
Dispatch Document Preparation No of Docket
First Step
Inbound Pre-Alert received from Celio Team
Check for any Priority received from the Celio Team on the Inbou

Login Celio System


Pick the Trolley with material & go to in Rack Area.
Outbound Pre Alert received from the Celio Team on Email

Pick List handed over by the Outbound Supervisor to the Picker


Picked Material in the staging area moved along with pick List to
the scanning station
Scanned Pieces received from the scanner along with system
generated packing list
After scanning system given pick confirm in the Celio system for
generate invoicing
WMS User To Take Print of Invoice
Find free location from system
Still Return Inbound Pre-Alert not received from Celio Team
Vehicle place at unloading point for unloading the vehicle
Login Celio System

Physically process after Return GRN to put way movement in the


location
Return Materiel Pick list Generation in the Celio
Pick List handed over by the Outbound Supervisor to the Picker

Picked Material in the staging area moved along with pick List to
the scanning station

Scanned Pieces received from the scanner along with system gene

After scanning system given pick confirm in the Celio system for generate invoicing

WMS User To Take Print of Invoice


Last Step
Verified document handover to floor supervisor.
Security Supervisor handover return inward documents to Inbound supervisor.

Generate Document Number/Scanning done in the Celio System


Handover the checked packing list to inbound supervisor
Generate Sales order OR transfer order for generating pick list.

Move the Picked material to the Scanning Staging area and place the pick list on the pallet

Scanned Pieces handed over to the Packer along with system generated packing list

Material Move to Dispatch Staging Area.

Dispatch Supervisor to check the Tax invoices and handover the signed copies to the transporter
Dispatch details Updating in Celio System
Rechecking Of Discrepancy.
Verified document handover to floor supervisor
Security Supervisor handover return inward documents to Inbound supervisor
Generate Document Number/Scanning done in the Celio System

Handover updated put away sheet to Return Inbound Supervisor


Generate Sales order OR transfer order for generating pick list
Move the Picked material to the Scanning Staging area and place the pick list on the pallet

Scan the verified Stock and change the Status from picked to scanned

Material Move to Dispatch Staging Area.

Dispatch Supervisor to check the Return Tax invoices and handover the signed copies to the transporter

Dispatch details Updating in Celio System


Cycle Time/Workload Driver Jan-15 Feb-15 Mar-15 Apr-15 May-15 Jun-15 Jul-15
15 to 16 minute
3.50 hrs to 4.00 hrs

08 minute
1 hrs 12 minute
10 minute

12 minute

4 minute

2.30 minute

10 minute

4 minute 45 second
45 second
15 minute

16 minute
1 minute 5 second
1 minute 55 second

4 minute

1 minute

050 second

4 minute 45 second
Aug-15 Sep-15 Oct-15 Nov-15 Dec-15
1 Order = 5000 units 250 boxes
1 Box = 20 units 8 Pallets

Sr. No. Steps Time (in min FTE


1 Pre-alert by mail 5 Flr. Sup.
2 Unloading vehicle 55 Picker
3 Scanning in Excel (Normal scanner) 207 Picker
4 Mail sent for PO arrangement (Only for Imports) 10 Flr. Sup.
5 Put-away sheet generation 5 Flr. Sup.
6 Physical Put-away 750 Picker
7 Put-away sheet updation in Excel 15 Flr. Sup.
8 Re-checking of put-away (HHT) 650 Picker
9 Generate retail receiving document for inward 10 Flr. Sup.
10 Post and confirm inward document 5 Flr. Sup.
11 Movement & GRN in Navision 15 Flr. Sup.
Total (in minutes) 1727.0
Total (in hours) 28.8

*empty boxes are left on the floor after putaway in the location and taking it back only after the entire

Vehicle
Sr. No. In Time
1 10:15
2 10:05
3 11:20
4 11:00
5 12:10
6 15:00
7 14:50

Scanning in Excel
Sr. No.
1
2
3
4
Avg.

Physical putaway

Sr. No. Start Time


1 12:10
2 1:55
3 2:30
4 2:40

Put-away Recheckin

Sr. No. Start Time


1 11
2 11.2
3 11.4
4 12
Total Mins Total Hours

Manpower
1
2
3
1
1
2
1
1
1
1
1

aking it back only after the entire process is over

Unloading

Total Qty. Time


Vehicle No. of As Per Required Time per
Out Time Boxes Weight Invoice (mins.) Qty./Box Box (mins.)
10:50 120 1800 2597 35 21.64 0.29
10:50 189 1811 1319 45 6.98 0.24
12:30 217 3255 3258 70 15.01 0.32
11:40 194 1239 6560 40 33.81 0.21
1:25 367 6000 6253 75 17.04 0.20
16:30 846 11776 9303 90 11.00 0.11
15:15 138 2070 5051 25 36.60 0.18
Avg. 20.30 0.22

Scanning in Excel
Time
Required
(mins.)
80
70
90
70
77.5

Physical putaway
Time Time per
Reqd. piece
Quantity End Time (mins.) (mins.)
310 1:00 50 0.16
223 2:20 25 0.11
261 3:10 40 0.15
333 3:35 55 0.17
Avg. 0.15

Put-away Rechecking
Time Time per
Reqd. piece
Quantity End Time (mins.) (mins.)
150 11.2 20 0.13
140 11.4 20 0.14
155 12 20 0.13
175 12.2 20 0.11
Avg. 0.13
1 Order = 300 units 12 boxes
1 Box = 25 units
1 Order = 250 orderlines

Waiting 60 mins. between picking & scanning

Sr. No. Steps (SAS) Time (in min FTE Manpower


1 Printing Picklist 10 DEO 1
2 Physical Picking 138 Picker 1
3 Scanning & Packing 88 Picker 1
4 Order Posting in Navision 10 DEO 1
5 Generating Packing Slip 5 DEO 1
6 Pasting Packing Slip 5 Picker 1
7 Invoice Generation for SAS (by KN) 10 DEO 1
8 Printing the Invoice 10 DEO 1
9 Box Packing in Gunny bags 30.75 Picker 2
10 Handover to transporter 10 Picker 1
Total (in minutes) 315.93195
Total (in hours) 5.27

* NOT ALWAYS the Picking is not done as per the picklist order

*Picking done as per the pick path-line on picklist, but not as per the physical layout.

Picking

Sr. No. Start Time Quantity


1 10:45 184
2 11:15 53
3 11:15 81
4 11:20 58
5 11:25 99

Scanning & Pa

Sr. No. Start Time Quantity


1 10:55 131
2 14:00 60
3 14:10 47
4 14:15 43
5 14:25 62

Gunny Bag Packing

Sr. No. Start Time No. of Boxes


1 11:00 6
2 11:20 8
3 11:45 8
4 12:05 6
rder

Picking
Time per Time per
Time Reqd. orderline piece
Orderline End Time (mins.) (mins.) (mins.)
138 11:47 62 0.45 0.34
51 11:45 30 0.59 0.57
75 11:50 35 0.47 0.43
50 11.55 35 0.7 0.60
87 12:00 35 0.40 0.35
Avg. 39.4 0.52 0.46

Scanning & Packing


Time per Time per
Time Reqd. orderline piece
Orderline End Time (mins.) (mins.) (mins.)
125 11:45 50 0.4 0.38
54 14:15 15 0.28 0.25
34 14:25 15 0.44 0.32
34 14:30 15 0.44 0.35
46 14:35 10 0.22 0.16
Avg. 21 0.36 0.29

Gunny Bag Packing


Time
Reqd. Time per box
End Time (mins.) (mins.)
11:16 16 2.7
11:37 17 2.1
12:01 17 2.1
12:25 20 3.3
Avg. 2.56
1 Order = 1500 units 75 boxes
1 Box = 20 units

Sr. No. Steps (SIS) Time (minutes)


1 Checking of documents 10
2 Unloading the vehicle 17
3 Re-checking of torn boxes (10% boxes torn) 10
4 MIS Updation 5
5 Scanning (in Excel) 208
Scanning details sent to customer for Inv
6 Sales Return documents 10

7 Post the scanned data in Navision 15


8 Retail Put-away sheet generated in Navision 10
9 Registering of Put-away (GRN Complete) 15
10 Quality Checking (OK/ Damaged) 0
11 Refurbishing of OK Goods (Top wear) 0
12 Re-packing of OK Goods (Bottom wear) 0
13 Final scanning and put away (HHT) 158.6
Total (in minutes) 431
Total (in hours) 7.19

Initial Scanning

Sr. No.
1
2
3
4
5
6
7
Sr. No.
1
2
3
4
5
6
7
buffer time of 60 mins added to scanning

FTE man power


Flr. Sup. 1
Picker 2
Picker 1
Flr. Sup. 1
Picker 1

Flr. Sup. 1

Flr. Sup. 1
Flr. Sup. 1
Flr. Sup. 1
(Done by Celio)
(Done by external staff)
(Done by external staff)
Picker 1

Initial Scanning Final Scanning


Time per
Time(mins.) Quantity piece(mins.) Sr. No. Time (Mins.) Quantity
1.5 15 0.1 1 1.7 20
1.8 15 0.12 2 1.85 20
1.55 20 0.08 3 2.5 25
2.5 20 0.13 4 1.3 15
5.9 46 0.13 5 2.7 25
6 46 0.13 6 60 370
15 100 0.15
Avg. 0.14 Avg.

Unloading
Total Qty. Time
Vehicle Out As Per Required
Vehicle In Time Time No. of Boxes Weight Invoice (mins.) Qty./Box
10:15 10:50 120 1800 2597 35 15
10:05 10:50 189 1811 1319 45 9.58
11:20 12:30 217 3255 3258 70 15
11:00 11:40 194 1239 6560 40 6.39
12:10 1:25 367 6000 6253 75 16.35
15:00 16:30 846 11776 9303 90 13.92
14:50 15:15 138 2070 5051 25 15
Avg.
Scanning
Time per
piece(mins.)
0.09
0.09
0.1
0.1
0.1
0.16

0.11
Time per Box
(mins.)
0.29
0.24
0.32
0.21
0.20
0.11
0.18
0.22
1 Order = 1500 units 60 boxes
1 Box = 25 units

Sr. No. Steps (SAS) Time (mins) FTE man power

1 Printing Picklist 5 DEO 1


2 Physical Picking 1051 Picker 1
3 Scanning & Packing 438 Picker 1
4 Order Posting in Navision 5 DEO 1
5 Generating Packing Slip for 60 boxes 20 DEO 1
6 Pasting Packing Slip on 600 boxes 60 Picker 1
7 Invoice Generation for SAS (by KN) 15 DEO 1
8 Printing the Invoice 10 DEO 1
9 Box Packing in Gunny bags 154 Picker 2
10 Handover to transporter 15 Picker 1
Total (in minutes) 1773
Total (in hours) 30

Pickin

Sr. No. Start Time Quantity


1 10.45 154.0
2 11.15 60.0
3 11.20 34.0
4 11.25 58.0
5 11.25 70.0
Scanning &

Sr. No. Start Time Quantity


1 10.55 131.0
2 14.00 60.0
3 14.10 47.0
4 14.15 43.0
5 14.25 62.0

Gunny Bag Packing

No. of
Sr. No. Start Time Boxes
1 11 6
2 11.2 8
3 11.45 8
4 12.05 6
Total Mins Total Hours FTEs

Picking
Time Time per Time per
Reqd. orderline piece
Orderline End Time (mins.) (mins.) (mins.)
111.0 11.50 65.0 0.6 0.4
55.0 11.45 30.0 0.5 0.5
30.0 12.00 40.0 1.3 1.2
50.0 12.05 40.0 0.8 0.7
63.0 12.15 50.0 0.8 0.7
Avg. 45.0 0.8 0.7
Scanning & Packing
Time Time per Time per
Reqd. orderline piece
Orderline End Time (mins.) (mins.) (mins.)
125.0 11.45 50.0 0.4 0.4
54.0 14.15 15.0 0.3 0.3
34.0 14.25 15.0 0.4 0.3
34.0 14.30 15.0 0.4 0.3
46.0 14.35 10.0 0.2 0.2
Avg. 0.4 0.3

Gunny Bag Packing


Time Time per
Reqd. box
End Time (mins.) (mins.)
11.16 16 2.67
11.37 17 2.13
12.01 17 2.13
12.25 20 3.33
Avg. 2.56
Supervisor Picker DEO Units
Fresh Inbound #REF! #REF! 0 5000
Fresh Outbound 0 0.00 0.00 5000
Returns Inbound #REF! #REF! 0 1500
Returns Outbound 0 0.00 0.00 1500
Total #REF! #REF! 0.00 13000
Round-off 1 27 3