A consulting study done to outsource the logistics activities of ABRL.

1. Retail Solutions, Supply Chain Solutions Group, WWL
Retail Logistics Solutions for ABRL
Presented By
Supply Chain Solutions Group
Worldwide Logistics (India) Pvt Ltd
Mumbai.

2. Retail Solutions, Supply Chain Solutions Group, WWL
Introduction to WWL Group
Sea Consolidation - FCL/LCL
• TGX Logistics Pvt Ltd
•
• Groupage Boxes
• NVO
• Liner Agency
• Liquid/Gas ISO containers
• Worldwide Logistics
(India) Pvt Ltd:
• International Freight
Forwarding - Air & Sea
• Warehousing & Distribution -
Intl’ & Domestic
• 4 PL Integration Services • Worldwide Centre for
Logistics Excellence Pvt Ltd
• Education
• Consulting
• Support Services
• Corporate Training
• MDPs in Logistics, Retail & SCM
• Trans Global Logistics
• Custom Brokerage
• Bonded Warehousing
• Documentation
WWL provides specific 3PL and 4PL solutions to integrate the Supply Chain

3. Retail Solutions, Supply Chain Solutions Group, WWL
Supply Chain Solutions Group outsource specific logistics functions
Functions where WWL can partner for Outsourcing
Distribution Transportation Logistics Order Mgt. Materials Mgt International
Logistics
others
Channel mgmt
and strategy
Transport
Planning/Modeling
Inbound
logistic
Customer
Service
Demand Planning Custom Mgmt IT
Infrastructur
e and
Strategy
Warehousing Shipment
Planning
Outbound
logistics
Order Entry/
Order
Processing
Distribution
Requirements
Planning
Freight
forwarding
Outsourcing
opportunities
Cross-docking Carrier Selection/
Mgt
Reverse
logistics
Technical
Support
Purchasing/
Expediting
Break -bulk External
environment
scan
Out/In bound Mgt Kitting
/Subassembli
es
Claims Mgt Inventory mgmt
Manpower
requirement
study
Track & Trace Logistics
performance
mgmt
Invoicing Inventory Accuracy
& Control
Industry
bench-
marking
Financial Mgt Network
design
Stores mgmt
Event Mgt
Logistics
organization

4. Retail Solutions, Supply Chain Solutions Group, WWL
Evolution of Logistics needs in Retail
Modern
Formats/
International
Weekly Markets
Village Fairs
Melas
Convenience Stores
Mom and Pop/Kiranas
PDS Outlets
Khadi Stores
Cooperatives
Exclusive Brand Outlets
Hyper/Super Markets
Department Stores
Shopping Malls
Traditional/Perv
asive Reach
Government
Supported
Historic/Rur
al Reach
Source of
Entertainme
nt
Neighborhood
Stores/Conveni
ence
Availability/
Low Costs /
Distribution
Shopping
Experience/Effici
ency
Served by the Stockists Network.
Stockists served by the C&Fs.
C&F provides break bulk convenience.
This segment
needs new age
competencies
of Continuous
Replenishment

5. Retail Solutions, Supply Chain Solutions Group, WWL
Customers
• IFB AUTOLIV LIMITED – AUTOMOTIVE
• IFB AUTOMOTIVE LTD – AUTOMOTIVE
• AVTEC LTD – AUTOMOTIVE
• RANBAXY LTD – PHARMA
• BAYER HEALTHCARE LTD – PHARMA
• INEXIOS PHARMA LTD – PHARMA
• NITCO TILES LTD
• TITAN INDUSTRIES LTD – FASTRACK PRODUCT
• CHEVRON INDUSTRIES LTD – LUBRICANTS
• GENERAL MILLS LTD – PILSBURY ATTA
• AREVA T&D LTD – SWITCH GEAR
• ABRL – RETAIL (MANGALORE)
• ABRL – KOCHI
• ABRL - VIZAG
• PYRAMID RETAIL - KOCHI
• HSRIL – RETAIL
• PANTALOON RETAIL – MANPOWER & TRAINING
• RELIANCE – MANPOWER & CONSULTING.

6. Retail Solutions, Supply Chain Solutions Group, WWL
DC Org - Managerial
DC Manager
Asst. Manger
Inbound
Asst. Manager
Outbound
Asst. Manager
Process and
Documentation
Supervisor- Inbound Supervisor- Inbound
Supervisor-
Picking team
Supervisor-
Staging area
Rout Manager
Supervisor-
Documentation
Supervisor-
Inventory
Management
Supervisor-
Returns and MIS
Supervisor-
Transport& Stores

7. Retail Solutions, Supply Chain Solutions Group, WWL
Process – Staging for Receipt
Asst Manager – Inbound (1)
Supervisor - Inbound (1)
Receipt Checkers (8)
Inward documentation clerks (4)
1. Generation of Inward Receipt at the Gate (Security)
2. Yard Management for Vehicle docking.
3. Unloading of Materials from the Truck – (By Vendor)
4. Visual Inspection & Dimensional Integrity check
5. Segregation of Visual Damages & POD acknowledgement
6. Open Inspection of Damaged if required and documentation for Claims.
7. Post inspection Labeling of Cartons or Products (If practiced)
8. Scan/ Manual Entry for Generation of GRN.
9. Inbound Document scrutiny, Report Creation and filing of documents.

8. Retail Solutions, Supply Chain Solutions Group, WWL
Process – Putaway
Asst Manager – Inbound (Put away)
Supervisor - Inbound
Putaway Crew (15)
1. Generation of Putaway runsheet from 3PL system
2. Unpacking/ Palletizing/ Crating
3. Segregation into Put away trolleys as per Put away Run sheet.
4. Physical Process of Put away as per suggested Locations.
5. Put away run sheet Confirmation.
6. Replenishment from Mother Locations to Fast Pick locations.
7. Rack Location Labelling & Part Location mapping supervision.
8. Pallet splitting & unit level replenishment to Fast Pick area
9. Updating Put away run sheets & Replenishment requests to fast pick
area.

9. Retail Solutions, Supply Chain Solutions Group, WWL
Process – Out Bound Picking
Asst Manager – Outbound (Picking)
Supervisor - outbound
Picking Crew (15)
Dispatch checkers (15)
Out Bound Documentation Clerks (4)/ (6) – Manual entry
1. Checking for Store Indents.
2. Creation of the STO (Stock Transfer Orders)
3. STO  Picklist Creation (Batch) – Zone wise Picking
4. Unit Level Picking from Fast Pick Area
5. Box level picking from the Bulk Pick area.
6. Handing over the pick trolley to the Staging for Dispatch area with PL
7. Dispatch Checkers Segregate the skus and crate it Indent wise for
dispatch and create Load Plan area truck wise.
8. Scan products crated and ready to dispatch for Picklist Confirmation.
9. Alternately data enter all lines picked for quantity and corrections.
10.The picked and crated material is handed over to the shipping
Supervisor.

10. Retail Solutions, Supply Chain Solutions Group, WWL
Process – Out Bound Shipping
Route Manager
Supervisor – Transport & MIS
Loading Crew (15)
Transport Documentation Clerk - 2
1. Counting and Loading of Crates to the Truck
2. Documents for Transit – STN/ VAT Form
3. Documents for Store acknowledgement
4. Safe Stacking of Crates inside the Truck.
5. Truck routing for Delivery to Stores.
6. Delivery Boys for counting and handing over of crates to the stores.
7. Return Crates loading
8. Accounting for return crates.
9. Return materials handling from Stores.
10.Returns Handling (Scrapping / Taking into Stock and returning to the
location for Pick)

11. Retail Solutions, Supply Chain Solutions Group, WWL
Process - MIS and Documentation
Supervisor – Inbound
Supervisor – Returns
Supervisor – Transport & Imports
Data Entry Operators (10)
1. Inbound Transport documentation – PO, Packing List, LR
2. Claims management for Damages/ shortages in Inbound Material.
3. Label generation for inbound materials.
4. Putaway Runsheet Creation.
5. Store Indent processing
6. STO creation
7. Picklist creation
8. Transport documentation creation.
9. Data Entry of receipts and issues
10.MIS creation for 3PL and ABRL.

12. Retail Solutions, Supply Chain Solutions Group, WWL
Process – Cycle count and Inventory Management
Supervisor – Inventory Management
Cycle count clerks (5)
Data Entry Operators (2)
1. Perpetual Inventory count in agreement with ABRL norms.
2. Monthly 4 wall count
3. Discrepancy Management - Within Warehouse
4. Discrepancy Management – Store reconciliation.
5. STN checking for non dispatch.
6. STN warehouse to GRN Store checking for acceptance of material
dispatched.
7. Quality Initiatives like 5S implementation

13. Retail Solutions, Supply Chain Solutions Group, WWL
Work Flow Assumptions
• Receipts from Vendors shall be taken from 10 AM and the Last
truck will be docked by 4PM for receipt.
• Inbound Receipt team shall be on duty from 10 AM to 4 PM.
• The store indents will be received before 10 am.
• The Out bound team shall work from 12 Noon to 8PM.
• Warehouse Manager, MIS, Documentation will work in the
general shift of 9 am to 6PM
• Inventory Team and Transport Management Team and crates
handling will work in the night shift from 10pm to 6am.
• Only one delivery to store per day which leaves the warehouse
by 5 AM in the morning.
• Round the clock Security will be provided
• 12000 LINE ITEMS TO BE PICKED FOR 20 STORE INDENTS.
• RECEIPT AND ISSUES WILL BE SCANNED IN TO THE SYSTEM.
THE SYSTEM INTEGRATION TO 3PL WMS IS ASSUMED.

14. Retail Solutions, Supply Chain Solutions Group, WWL
Manpower allocation
SL NO MANPOWER SHIFT 2
12 NOON – 10
PM
SHIFT 3
10PM TO 6AM
GENERAL
SHIFT
9 – 6 PM
1 Warehouse Manager, MIS team,
Maintnanence, Office Staff
2 Asst manager Inbound,
Supervisors, Checkers and
Putaway crew + Data entry
Operators
3 Asst Manager – Out bound,
Supervisors, Checkers and
Pickers + DEO
4 Transport supervisor, Transport
documentation, Loaders,
Inventory Managers
5 Security – 8 Guards + 2
Supervisors

15. Retail Solutions, Supply Chain Solutions Group, WWL
Total Manpower Strength
Sl. No Position Count
1 Project (DC) Manager 1
2 Asst Managers 5
3 Supervisors 5
4 Skilled Workers 30
5 Semi Skilled 28
6 Labour 20
7 Data Entry Operator 24
8 House Keeping 5
9 Security (Incl Supervisor) 10
TOTAL 128

16. Retail Solutions, Supply Chain Solutions Group, WWL
Proposed Layout – Mettler Fishbone
STAGE FOR RECEIPT
STAGE FOR DISPATCH
SHELVING AREA FOR UNIT/FAST PICK
HD RACK AREA FOR
BULK PICK
HD/OPEN BAY
PALLET POSITIONS
Gravity Flow Shelving – 50%

17. Retail Solutions, Supply Chain Solutions Group, WWL
Suggested Part-Location Mapping
• BOX in BOX out – HD/ Stack on Pallet.
• BOX in BOX out frequent pick – Gravity Rack
• Unit level pick (frequent) – Flat crate on Gravity
Rack.
• Bulk storage and slow Moving – HD Rack.
• High Velocity Unit Level pick sku – Shelving
G+3

18. Retail Solutions, Supply Chain Solutions Group, WWL
Static Shelving Vs Gravity Flow
Factor
Gravity Flow Static
Shelvin
g
Gain w/
Gravity Flow
If total floor space is equal equal -
Then items stored (each case, 1 cubic foot) 155 120 29%
Shelves high 5 3 2
Cases per opening 15 12 3
Total cases 2325 1440 61%
15% Productive time
85% Productive Time

19. Retail Solutions, Supply Chain Solutions Group, WWL
Stages in Layout Design
WWL
1. Zoning – Based on
Product Category
2. Storage Device Selection
– Static/ Gravity flow/
HD/Pallet
3. Mapping the Storage
Device to Zone.
4. Mapping the Location to
Storage Device/ Bay
5. Mapping Part (SKU) to
Location.
6. Define Staging areas
7. Marking of Aisle
ABRL
1. Category of Product (As
of Today)
2. SKU (Number) per
Category.
3. MOQ of each SKU
4. Alternately, Min Max
defined inventory level of
each SKU.
5. Store replenishment
pattern for products.
6. Sample pull order from
Store.
7. MOQ of store orders.

20. Retail Solutions, Supply Chain Solutions Group, WWL
Pick Methods
1. Batch Pick – SKU level batching of products
done from Store Indents and Picklists created.
Reduced complexity of pick and reduced
manual errors of pick counts.
2. Wave Pick – Will be practiced when the pick
volume is less and during lean period. This
increases the turnaround time of picking large
volumes inside the warehouse.
3. Pick&Pass – After studying the store orders and
the complexity of the process and once the
Fast Pick area concept is validated, the process
can be automated using conveyors.

21. Retail Solutions, Supply Chain Solutions Group, WWL
Recruitment & Training
Centre of Logistics Excellence, Bangalore Campus
• 25 Acre Institute houses 500+ students at a time.
• 10, 10+2 students have been taken from various part of
South India and trained.
• Can recruit semi skilled and Labours are taken Locally
• Supervisors and Semi Skilled are taken through
recruitment from other project and market through
agencies.
• Team of 66 persons trained and currently working in the
backend of modern retail formats available.
• COLE can run continuous training programs with its faculy
based in south and West.

22. Retail Solutions, Supply Chain Solutions Group, WWL
Critical Challenges
1. Warehouse Layout to reduce number and stress level of
manpower deployed.
2. Reduce Manual entry mistakes and put away/ Pick
irregularities.
3. Timeliness of documentation and correction of inventory
discrepancies.
4. Deployment of Handheld Scanners for data capture.
5. Part location mapping and fixing of Min Max inventory
levels for part storage.
6. MOQ for delivery to stores.
7. Crate recycling from Stores.
8. Training and Skill enhancement programs for Pickers to
build a second line constantly.

23. Retail Solutions, Supply Chain Solutions Group, WWL
Data required to give the final Plan
1. Warehouse Floor Plan
2. Details in the slide – Design of Layout
3. Familiarization with the existing IT system to
map the process to physical implementation.

24. Retail Solutions, Supply Chain Solutions Group, WWL
Profile
• Turnover – 110 Cr. (WWL Group)
• Branches – 23
• Manpower strength – 230 (Direct)
400 (Indirect)

25. Retail Solutions, Supply Chain Solutions Group, WWL
New Initiatives
• Have created a Joint Venture company with Rogers Group
(Mauritius/France) to address growth in the INDIAN OCEAN RIM. •Have
signed up NVO Agency agreement with the TATA Group to represent their
interests in Cochin, Mundra, Tuticorin, Kandla.
•Have entered into strategic agreements with a Singapore based shipping
line to operate in Niche Markets like ISO containers and gas /crude
transportation.
•Have successfully secured licenses from FEDERAL MARITIME COM
MISSION, USA which will help the group to cater to the North
American Market with our own presence.
• Launched the project for Worldwide Logistics Park - An integrated
warehousing facility at Chennai.
•Supply Chain Services Group started operations and today have 4 projects
under execution.
•Strategic Partnership with CJ GLS (5Bn Dollar Asian Logistics
organization) for asset based expansion of 3PL function.

26. THANK YOU
Saleesh S
Retail Solutions, Supply Chain Solutions Group, WWL