1. Convert Waste into Value using OTM
Value IN Waste OUT
Get More form your OTM

2. Boxing Bout
Mr. TIMWOOD Mr. OTM

3. Who is Mr TIMWOOD?
Inventory
Transportation
Motion
Defects 7 Deadly
Wastes
Waiting
Over
Processing
Over
Production
STRATEGY :-
Distracts you and attacks with
• SHORT JABS
• BACK HAND PUNCH
• TWIST PUNCH

4. Mr TIMWOOD is all prevalent
Waste What is it? Examples
Transportation • Unnecessary transportation • Moving over longer distances than
moves required.
Inventory • Excess resources deployed • Under-utilised Vehicle /
than required Equipment
Motion • Actions of people or • Manual Data Entry
equipment that do not add • Misalignment of Dock scheduling
value to the process with staging point
Waiting • Materials not moving • Order stuck in a queue
• People waiting for work • Staging of packages
• Vehicle waiting to be handled

5. Mr TIMWOOD is all prevalent
Waste What is it? Examples
Over-Production • Producing more than • Moving packages through express
is actually required when normal mode can meet
delivery date
Over-processing • Working beyond what • Adjustments of shipment units in a
is needed to satisfy container
the customer • Re-checks in process
• Any unnecessary steps • Duplication of Data Entry
in processing
Defects • To work over again, to • Rework
revise, to repeat a • Rejects
process usually to
correct an error

6. Mr OTM = Mr DEPENDABLE
BEST ENDURING
PRACTICE; WASTE SUSTAINABLE
THEORY REMOVER OPERATIONS
OTM provides the Capability to Continuously Improve & Sustain Operations
STRATEGY :-
CONSISTENT ATTACK TO TIRE OUT THE OPPONENT
• STRAIGHT RIGHT AND LEFT HOOK
• HOOK PUNCH
• UPPER CUT

7. Plan before the Bout :
Value Stream map : Logistics Operations
ADC
Manual
Verbal
Orders to suppliers
Parts Kitting TMS
Special dixs
Customers
CT: 18 mins
ERP CT: xxxxx
Outlets / Dist
People 13 ERP Planning People xxxx Consignment
Shifts : 2 Shifts : 2 Freq: daily 25/30
Load : 5000
Mtrs ps ERP Load : xxxxx Total qty items:
ERP NA
Discrepancy ERP ERP
report
Daily Non Invoice + LR
availability TMS
TMS
Goods Sorting and Packing Weighing
Binning Zone wise Scanning Consolidation
Receipt Merging
Staging
CT: 5 mins CT: 12 mins CT : 16 mins: CT: 6 mins CT: 2 mins CT: 2 mins
CT: 2 mins CT: 8 mins
People: 1/2 People: 1/6 People: : 1/20 People 1/4 People
People 2/4
People:: 2/2 People 3/12
Batch size -SKU Batch size-SKU Batch :-86 mtrs Batch – 86 mts
Batch – Pick list Batch – Ship Unit Batch – Ship Unit
Load :- 40000 Load :- 40000 Load40000 Shifts 2,
Load : 200 pd Load4 0000 Load – 1000 Load – 1000
Mtrs per day Mtrs per day Mtrs pd mtrs pd : : Bales pd Bales pd
NVA
45 mins 24 mins .45-60 days 60 mins .32 mins 25 mins .20 mins 45 mins
VA 5 mins 12 mins 2 mins 16 mins 6 mins 8 mins 2 mins 2 mins
TIM WOOD had created 82% waste in the operations

8. 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 • Ordering excess capacity due to lack of visibility
Production
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

9. Let the match begin
Mr. OTM Mr. TIMWOOD
BOX

10. 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

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

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

13. Removing the “Inventory” Waste by using
container space optimally : Loading Pattern
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
Pinwheel
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
Crosswise Standing Straight
blank, then no restrictions apply.
Loading Patterns* specify the orientation and
layout for when ship units are loaded in Standing Nested Lengthwise
equipment.
Canon Rolling

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

15. 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

16. 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

17. 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

18. 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

19. Removing “Over Process” Waste of Data Entry of
Manual Invoices by using conversion and loading tools
Manual / PDF / Excel format XML format
Process Scanned Invoices Invoices Invoices
Received received received
Invoice Manual Manual ( Excel )
Registration
Invoice and POD Manual Upload Data Upload
Data Entry
OTM OTM OTM
Verification
• High Manpower Cost • Data Upload Errors
• Inaccuracy • Mapping Errors
• Training • Infrastructure Cost

20. Removing “Over Process” Waste of Data Entry of
Manual Invoices by using conversion and loading tools
Manual / PDF / Excel format XML format
Process Scanned Invoices Invoices Invoices
Received received received
Invoice Scan Excel to XML
Registration converter
Invoice and POD Digitize, Map & Map & Load Map & Load
Data Entry Load
OTM OTM OTM
Verification

21. Removing “Over Process” Waste of Data Entry of
Manual Invoices by using conversion and loading tools
Fetch Map Web-service
Digitize Load XML
iFetch iCap LoadX OTM
• FTP based fetch • Digitize correct • Mapping Accuracy • Freight Settlement
• OCR convert If required • Loading accuracy
• Inbuilt intelligence • Error window
TIMWOOD send back to the Corner before round ends

22. 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

23. Removing “Defect” and “Wait” Waste leading to
damages and demurrage charges by using Mobile sols
Web Service Map Web-service
Load
OTM POD App LoadX OTM
• Despatch Data • Transshipment • Mapping Accuracy • Freight Settlement
Transfer Integrity • Loading accuracy
• Shortage / damage • Error window
Integrity
• Arrival times
• Demurrage
Management
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
Process Flow Bar Code scan functionality
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
TIMWOOD is on Count of 10

24. KNOCK OUT
Waste Out Value In
Mr. TIMWOOD Mr. OTM

25. 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