Convert Waste into Value using OTM

Value IN Waste OUT

Get More form your OTM

Boxing Bout Mr. TIMWOOD Mr. OTM

Motion

Transportation

Waiting

Over Processing

Over Production

Defects

Inventory

7 Deadly Wastes

Who is Mr TIMWOOD?

STRATEGY :- Distracts you and attacks with • SHORT JABS • BACK HAND PUNCH • TWIST PUNCH

Mr TIMWOOD is all prevalent

Waste What is it? Examples

Transportation • Unnecessary transportation moves

• Moving over longer distances than required.

Inventory • Excess resources deployed than required

• Under-utilised Vehicle / Equipment

Motion • Actions of people or equipment that do not add value to the process

• Manual Data Entry • Misalignment of Dock scheduling

with staging point

Waiting • Materials not moving • People waiting for work

• Order stuck in a queue • Staging of packages • Vehicle waiting to be handled

Waste What is it? Examples

Over-Production • Producing more than is actually required

• Moving packages through express when normal mode can meet delivery date

Over-processing • Working beyond what is needed to satisfy the customer

• Any unnecessary steps in processing

• Adjustments of shipment units in a container

• Re-checks in process • Duplication of Data Entry

Defects • To work over again, to revise, to repeat a process usually to correct an error

• Rework • Rejects

Mr TIMWOOD is all prevalent

OTM provides the Capability to Continuously Improve & Sustain Operations

Mr OTM = Mr DEPENDABLE

STRATEGY :- CONSISTENT ATTACK TO TIRE OUT THE OPPONENT

• STRAIGHT RIGHT AND LEFT HOOK • HOOK PUNCH • UPPER CUT

SUSTAINABLE OPERATIONS

ENDURING WASTE

REMOVER

BEST PRACTICE; THEORY

Plan before the Bout : Value Stream map : Logistics Operations

Daily

Goods Receipt

CT: 5 mins

People: 1/2

Batch size -SKU

Binning

CT: 12 mins

People: 1/6

Batch size-SKU

Load :- 40000 Mtrs per day

Sorting and Merging

CT : 16 mins:

People: : 1/20

Batch :-86 mtrs

Weighing

CT: 2 mins

People 2/4

Batch – Ship Unit Load – 1000 Bales pd

Consolidation

CT: 2 mins

People

Shifts 2,

Planning

Customers

Outlets / Dist

Consignment

Freq: daily 25/30

Total qty items:

Discrepancy report

ERP

ERP

NVA VA 5 mins 12 mins 2 mins 16 mins 6 mins 8 mins 2 mins 2 mins

45 mins 24 mins .45-60 days 60 mins 25 mins .20 mins 45 mins .32 mins

Zone wise Staging

CT: 2 mins

People:: 2/2

Batch – Pick list

Load : 200 pd

Non availability

ERP

Scanning

CT: 6 mins

People 1/4

Batch – 86 mts

Packing

CT: 8 mins

People 3/12

Batch – Ship Unit

Load – 1000 Bales pd

Orders to suppliers

Load :- 40000 Mtrs per day

ERP

NA

Parts Kitting

CT: 18 mins

People 13

Shifts : 2

Load : 5000 Mtrs ps

ERP

TMS

Load40000 Mtrs pd

Load4 0000 mtrs pd : :

ERP

TMS

Special dixs

CT: xxxxx

People xxxx

Shifts : 2

Load : xxxxx

TMS

Invoice + LR

Manual

Verbal

ADC

TIM WOOD had created 82% waste in the operations

TIMWOOD had attacked multiple areas

Waste Waste Identified

Transportation • Multiple vehicles routed to same region on same day • Last minute changes in plans necessitated by business was

leading to excess transportation moves

Inventory • Vehicle capacity was not effectively utilised

Motion • Repetitive Manual planning entry was slow , errors and unproductive

Waiting • Manual Dock scheduling resulted in wait time & demurrage

Over Production

• Ordering excess capacity due to lack of visibility

Over Process • Manual Invoicing by carriers led delayed payments & leakages • Ship Unit re-loading, adjustments after loading a container to

optimise space utilisation

Defect • Transhipments of critical items led to product damages • Fitment Parts were left out while the main assembly was shipped

Let the match begin

Mr. TIMWOOD Mr. OTM

BOX

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

Removing the “Inventory” Waste by using container space optimally : 3D Output

Removing the “Inventory” Waste by using container space optimally : Handlers Output

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

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 blank, then no restrictions apply. Loading Patterns* specify the orientation and layout for when ship units are loaded in equipment.

Pinwheel

Removing the “Inventory” Waste by using container space optimally : Loading Pattern

Crosswise

Lengthwise Standing Nested

Standing Straight

Canon Rolling

Removing the “Inventory” Waste by using container space optimally : Tim Wood has a Black Eye

Removing the “Inventory” Waste by using container 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

Removing the “Defect” Waste of Fitment Parts left out while the main assembly was shipped using BOM Structure Fitment 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 not be repeated again and again. The BOM data can be pulled 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

Removing the “Transportation” Waste to cater to last minute 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 VTS

TIMWOOD rises after a 3 count

Removing “Transportation” Waste of Multiple vehicles routed to same region on same day by using pooling Option Multiple Points are clubbed into a region and transit hubs 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

Removing “Over Process” Waste of Data Entry of Manual Invoices by using conversion and loading tools

• High Manpower Cost • Inaccuracy • Training

Manual / PDF / Scanned Invoices

Received

Excel format Invoices received

XML format Invoices received

Invoice Registration

Invoice and POD Data Entry

Verification

Process

Manual

Manual

OTM OTM

Manual ( Excel )

Data Upload

• Data Upload Errors • Mapping Errors • Infrastructure Cost

OTM

Upload

Manual / PDF / Scanned Invoices

Received

Excel format Invoices received

XML format Invoices received

Invoice Registration

Invoice and POD Data Entry

Verification

Process

Scan

Digitize, Map & Load

Excel to XML converter

OTM OTM OTM

Map & Load Map & Load

Removing “Over Process” Waste of Data Entry of Manual Invoices by using conversion and loading tools

Web-service

XML

Map

Load

Fetch

Digitize

iFetch • FTP based fetch • OCR convert

iCap • Digitize correct If required • Inbuilt intelligence

LoadX • Mapping Accuracy • Loading accuracy • Error window

OTM • Freight Settlement

TIMWOOD send back to the Corner before round ends

Removing “Over Process” Waste of Data Entry of Manual Invoices by using conversion and loading tools

Removing “Defect” and “Wait” Waste leading to damages and demurrage charges by using Mobile sols Equipment# / LR# and Vehicle# on departure from the plant 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

Web-service

Map

Load

Web Service

OTM • Despatch Data

Transfer

POD App • Transshipment

Integrity • Shortage / damage

Integrity • Arrival times • Demurrage

Management

LoadX • Mapping Accuracy • Loading accuracy • Error window

OTM • Freight Settlement

TIMWOOD is on Count of 10

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 Bar Code scan functionality

Process Flow 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

Removing “Defect” and “Wait” Waste leading to damages and demurrage charges by using Mobile sols

KNOCK OUT Waste Out Value In

Mr. TIMWOOD Mr. OTM

NEED HELP TO KOCK OUT

MR. TIMWOOD

CONTACT US AT

vikasg@hexaware.com contact no +44 7799644535

dhruvm@hexaware.com contact +49 1721617774

navals@hexaware.com contact no +91 9004014283

Visit us at Our OTM Lab at

Chennai, India