ISSUES AT WAREHOUSE
•Digestion problem –Warehouses took long time to inward the goods and even longer time to dispatch them.
•Unable to match demand –Stores experienced frequent stock outs despite goods being available at the warehouses. Problem even
more rampant during festive seasons.
•Late delivery by Vendors – Warehouses accepted even delayed consignments which was against the company’s stated policy.
•Planning issues –Since the vendors sent multiple shipments against single purchase orders, that too without any advance intimation,
warehouse could not plan its receiving process well.
•GRN process not followed –GRNs sometimes took 3-4 days which was against the company policy. Conformance to the company
policy was not very high.
•Consignment issues –Warehouses sometimes used to file wrong timing of receiving consignments which led to lack of clarity on
conformance to policies. Some consignments also had problems of wrong barcodes.
•Inventory issues –Actual inventory in the warehouses exceeded the target by 50 to 100%. Focus was to avoid stock outs rather
than avoiding excess inventory.
•Space Management –Company could not maintain keeping the items in their earmarked places. There was inventory in every
available spot in the warehouse.
•Inefficient picking process –Pickers spent a lot of time in completing the pick list because of the inventory being scattered at
different places.
•Error in system inventory –System would show item in stock despite no physical stock and vice versa.
•Low throughput –Company followed a piece-in and piece-out model because of which they had low throughput.
•High Packaging costs –Warehouses bought new cartons to send the goods to the stores which reduced the already thin margins of
the stores.