Summer Internship Report

(27/6/2018 – 20/7/2018)
Submitted by: Avishek Bhattacherjee
College: IISWBM
MBA-PS(Transportation and Logistics
Management)
Batch: 2017-2019
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CONTENTS:

Sl No. Slide Number Title of the Description

1 4 Acknowledgment
2 5 About the Company
3 6 LG Warehouse
4 7-10 Warehouse management system of LG Warehouse
5 11-14 Primary & Secondary Movement
6 15 LGEIL SOP
7 16 Abbreviation
8 17 LG Products
9 18-20 Operation Work Flowchart
10 21 Organisational Structure of Warehouse
Sl No. Slide Number Title of the Description
11 22-27 Documentation
12 28 Stacking
13 29-31 Stacking Norms & Practices
14 32 Cycle Count
15 33-35 RF Scanner
16 36-37 RDC , CDC and Area of Cater
17 38 Sub Inventory
18 39-40 Warehouse Layout
19 41 Advance Material handling equipment
20 42-45 Quality maintain basis and handing Norms
ACKNOWLEDGEMENT:

I am very thankful to Rajprotim Supply Chain Solutions Ltd for having given me
the opportunity to undertake my summer training at their New Gopalpur,
Sarkarpool LG Electronics India Ltd Warehouse. It was a very good learning
experience for me to have worked at this site as this project involved many unique
processes and challenges. I would like to utilize this opportunities to convey my
heartiest thanks to Mr. Kingshuk Bakshi, Operational head, who heartily welcomed
me for the internship.
I would also like to give my heart-felt thanks to Mr. Bijoy Kumar Pandey,
warehouse manager, who guided and encouraged me all through the summer training.
Last but not the least; I would like to thank all the staff at Rajprotim Supply Chain
Solutions Ltd for being so helpful during this summer training.
ABOUT THE COMPANY

• Rajprotim Supply Chain Solutions Ltd. is a leading C&F agent having a strong base in the
Eastern region of India. The company is known for providing supply chain solutions,
warehousing and logistics services.
• Their first C&F business started in 1984.
• The company initiated modern door delivery systems and the largest LCV operator in the
East.
• Acquired knowledge of supply procedures and adopted all best practices and graduated to
a Supply Chain service provider by expanding the scope of deliverables in the
conventional CFA business.
• The company offers warehousing and supply chain solutions to leading brands such as
LG, ITC, L'Oreal, Castrol, Johnson & Johnson, etc.
• It owns a fleet of over 600 own vehicles, managing 3 shift operation.
• Transportation wing is expanded as a step towards providing ‘Just In Time’ services.
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LG WAREHOUSE

• Situated in the suburbs of Kolkata, the warehouse is a 84000 sq.ft. area easily
accessible by road.
• LG operates 2 branches in West Bengal viz. Kolkata and Durgapur, but it physically
operates from the Kolkata warehouse.
• The manufacturing plants are situated in Pune and Noida.
• The Kolkata Region Distribution Centre caters to only West Bengal.

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Warehouse Management System in LG
A warehouse management system is the processes that allows an
organization to control and administer warehouse operations from the
time goods enter a warehouse until they move out of the warehouse.

For managing the operations of the warehouse, 3 soft wares are used.

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GERP- Global Enterprise Resource Planning

• GERP is the main software that monitors the other two soft wares (i.e.
GDLS & GWMS).

• Subsidiaries of LG worldwide enjoy improved visibility of critical business

data and significant reductions in account closing time and profitability
analysis time by using GERP.

• All documents and reports on inbound & outbound activities are procured
from GERP.

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GDLS- Global Digital Logistics Solution

• GDLS is used for generating Load Plan i.e. the list according to which the
products to be shipped are prepared for shipping.

• GDLS is also used for preparing Stuffing Instruction for material stuffing
dealer-wise, along with address, which facilitates load planning.

• IOD and POD are also punched into GDLS.

• GDLS is also used for freight processing and analysis.

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GWMS- Global Warehouse Management System

• GWMS is used in both inbound and outbound process for scanning the products to record
the product details into the system, allocating them to specified locations in the
warehouse, picking the products for dispatch, re-allocating them to different locations
when necessary, and finding a particular product’s location in the warehouse.

• GWMS is used for generation of Picking and Packing list.

• GWMS is also used for Cycle Count i.e. physically counting the stock of all the
transactions that have taken place on the previous day.

• GWMS was introduced in the LG warehouse 5 yrs ago.

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PRIMARY MOVEMENT

Manufacturing Hub to Warehouse

OEM/Imported items to Warehouse

Inter Branch Stock Transfer

Primary Transport

• Primary Transportation is inward movement of vehicles into the warehouse.

• It is always done on FTL mode i.e. a single truck contains a single consignment and not clubbed with
multiple consignments.
• FTL mode is used for volumetric products so that the number of times the product is handled is not
more than once or twice.
• If volume is not there, more volume is demanded to make the truck full.
• For small products, e.g. GSM, Projector, where multiple handling (3 to 4 times) can be permitted,
courier is used instead of truck. In courier service the materials are also given proper care while
handling.

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SECONDARY MOVEMENT

Warehouse to Customer

Warehouse to Dealer/Distributer

Inter Branch Transfer/ Stock Transfer

Customer Replacement (From Service Sector)

Sales Promotion/Demo/Exhibition (RGP)

Gift/Award/Marketing Stock (NRGP)

Secondary Transportation

• Secondary transportation is outward movement of vehicles from the warehouse.

• If small load is there, it is sent through Mixed load and charge is made on Per
Carton basis.
• If volume is there, FTL mode is used.
• 90% of Rajprotim’s business is done on Per Carton box basis.

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 LG Electronics India Ltd. SOP

1. Operational Activity management

1.1 Material Inward process (STN/Purchase/Sales Return)
1.2 Material Outward Process (STN/Invoice/RGP/NRGP)
1.3 IOD-POD Management
1.4 Inventory Management
1.5 Record Management

2. Process Management
2.1 RGP/NRGP Process
2.2 Sales Return
2.3 IOD-POD Process and Reconciliation
2.4 Commercial Process
2.5 Write Off Process
2.6 Insurance Process

3. Reports and formats Specimen

Abbreviation

STN = Stock Transfer Note

GRN= Good Receipt Note
SRN= Sales Return Note
ASN= Advance/Arrival Shipping Note
RGP= Non Refundable Gate Pass
NRGP= Non Refundable Gate Pass
IOD= Information Of Delivery
POD= Proof Of Delivery
WIP= Work In Progress
WMS= Warehouse Management System
LG Products Present In the Warehouse

Washing
TV Refrigerator AC Microwave Others Items
Machine
• LED • Direct Cool • Split AC • Grill • Top Load • Air Purifier
• Ultra HD • Frost Free • Commercial • Solo • Front Load • Water Purifier
• Ultra HD 4K • Dios AC • Convection • Semi • Projector
• Full HD Automatic • GSM
• OLED • Monitor
• Smart TV • Optical
Storage
Device
(CD/DVD
Drive)
• Dish washer
• Compressor
Operation Flowchart of LG warehouse

INPUT

PUT-AWAY
RECEIVING •Identify Product
•Unload Vehicle •Product Scanning
•Scan the Received •Put-away (Storage)
Products •Goods Receipt Note ORDER RECEIVING
•Inspect for (GRN) INFORMATION
damage •Pick slip generation
•Crate Space for •TransporterAssigning
Put-away SHIPPING
PREPARATION/
PICKING
•Picking
•Scan the products

SHIPPING
•Load Vehicle
•Bill of Loading DESPATCH
•Record Update
INBOUND PROCESS

LG Factory, CDC and

CBU/OEM Suppliers
other LG Branches
Purchase Invoice
STN
GRN
Vehicle Reported at
Dock Point
STN,INVOICE,LR,Packing List,
Vehicle Seal
ASN

Scanning of
Unloaded Units with
RF Scanner

Put way according to

GWMS Space GRN
Management
OUTWARD PROCESS

Load plan In Pick-Slip Put the Picked

Sales Order Physical Picking
GDLS Generation in Material near
GWMS Loading Dock
LR, INVOICE,
Waybill, Packing
List, Staffing Scan the
List, Picking List Packing Slip and Ship Confirm in Load Confirm
Invoice Products with RF
all these GDLS Scanner
documents given Generated in
to Transporter GERP

Vehicle release Physical Transporter

from Warehouse Details Uploaded IOD Punched
to Despatch Delivery Confirm IOD
Control Register
POD submitted Follow up with
at Warehouse the Transporter
for POD
ORGANISATION STRUCTURE FLOWCHART

Branch SCM

Rajprotim Supply Chain Solutions Ltd.

Transporter Vendor
CFA

Warehouse Manager TPT Representative

Assistant WH Manager

Computer Operator Document In charge Supervisors Insurance

DOCUMENTATION

 Inbound Movement

 GRN (Good Receipt Note)

Record of goods received at the point of receipt. This record is used to confirm all goods have been received
and often compared to a purchase order before payment is issued.

 Inbound Check List

A document accompanying a shipment of goods that lists the description, and quantity of the goods delivered.
A copy of the delivery note, signed by the buyer or consignee, is returned to the seller or consignor as a proof
of delivery.

 Unloading Acknowledgement

 LR Copy
LR Stands for Lorry Receipt also called “Bilti” in Hindi. This receipt is either in 3 copies or 5 copies i.e.
Consignee copy, Driver Copy, Consigner Copy and File Copy. This receipt is made by the Transporter once the
material is loaded on the vehicle for Delivery. The receipt contains the Vehicle Number, Pickup address,
delivery address, number of packages, material description, vehicle type, and date.
.
DOCUMENTATION Cont.

 Inbound Document

 Tax Invoice/ Purchase Order

Tax invoice is an invoice issued for taxable supply of goods & services. Tax invoice broadly contains details like
description, quantity, value of goods/service, tax charged thereon and other particulars as may be prescribed. Tax
invoice is a primary evidence for recipient to claim input tax credit of goods & service.
Purchase Order
A buyer-generated document that authorizes a purchase transaction. When accepted by the seller, it becomes a
contract binding on both parties. A purchase order sets forth the descriptions, quantities, prices, discounts,
payment terms, date of performance or shipment, other associated terms and conditions, and identifies a specific
seller.

 E-way Bill

 Packing List
Itemized list of articles usually included in each shipping package, giving the quantity, description, and weight of
the contents. Prepared by the shipper and sent to the consignee for accurate tallying of the delivered goods.
DOCUMENTATION Cont.

 Outbound Document

 Consignment Note
Document prepared by a consignor and countersigned by the carrier as a proof of receipt of consignment for
delivery at the destination.

 Tax Invoice/ STN

Stock transfer is the act of moving goods from one part of the distribution chain to another. An internal
purchase order is created for stock transfer between branches and warehouses.
 E-way Bill
 Packing List

 Staffing Instruction
This document contain Load No, Carrier Name, Chargeable Tonnage, Truck Type, Delivery Type, Truck No,
Driver Name, Driver Mobile Number, Ship-to-Name, Model, Grade, Order Quantity, Address of delivery.

 Picking List
Itemized list of articles usually included in each shipping package, giving the quantity, description, and weight
of the contents. Prepared by the shipper and sent to the consignee for accurate tallying of the delivered goods.
 Purchase Order
 E-way Bill

• E-way bill is a document required to be carried by a person in charge of the conveyance carrying
any consignment of goods of value exceeding (Rs. 50,000) fifty thousand rupees as mandated by
the Government.
• It is applicable both in 1. Sale of goods and payment made and 2. Branch Transfer.
• It is generated from the portal for E-Way bill (https://ewaybillgst.gov.in) system by the registered
person, unregistered person and transporter who cause movement of consignment before the
movement goods.
• E-way bill is valid for 24 hrs. for every 100 km.
• For the next 100 km., i.e., 101-200 km., additional 24 hrs.
e-way bill is required to be cancelled or extended within 24 hrs. of expiry.
• E-way bill is required to be modified/updated against transhipment of vehicle.

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 Vehicle Documentation
• Registration Certificate
• Insurance
• Tax Token
• Issued by the State Government
• Permit
• Issued by Government for 5 years, to run in the state
• Pollution Control (6 month)
• Driver’s Licence
• Driver’s authorization letter
• Certificate of Fitness
• CF is not required from the date of registration of the vehicle till 2 yrs.
• After 2 yrs CF is required and is renewed every year.
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STACKING:

 Stacking is the process of storing Materials or Product in a systematic norm for increasing the utilization of
the warehouse space, storing of the products without the risk of getting damaged, easy way to retrieve the
products and also it creates a better visual effect.

 In LG warehouse it is 100% palletization applied in storing and movement of the products.

 Wooden pallets are used for stacking all the electronic products( TV, AC, Refrigerator, Micro-oven, Air and
Water Purifier, Sound System etc.) Pallets are taken in rent basis from a company named LEAP.

 A standardize pallet has a length of 1400 mm and width of 1200 mm. Number of pallets currently in
warehouse is 3150.

 Products have written stacking limits in their carton box and all the products in the warehouse are stacked
according to the mentioned stacking limit.

 Boxes are made with layers of cardboard for prevention of getting dent. Currently it consist of 5 layers.

 This Warehouse follow FMFO (First Manufacturing First Out) basis for handling stock.
STACKING NORMS

Direction of
Gap between
Yellow Line Marking Maintaining the movement of pallet
successive pallets
Location Stacking Limit to and from a
row
location
STACKING NORMS Cont.

Velcro strap should be Shouldn’t overhang

Safe distance from the
tied up for stacking beyond 50mm on either Product Grouping
wall of the warehouse
materials side
Guidelines for Storing the Materials Location wise:
CYCLE COUNT

 Cycle Counting are done on daily basis in every morning before the Inbound and
Outbound movement start taking place.
 Cycle Counting are done only on the locations and the models which were
involved in inbound or outbound movement that took place the day before.
 Cycle count can determine the discrepancies in the warehouse’s physical stock and
system stock input.
 It is easy to determine the origin of mismatch through Cycle Counting as number
of transaction daily is lesser in number.
 Cycle Counting are done physically by visiting all the location mentioned in the
WMS.
 Cycle counts are less disruptive to daily operations, provide an ongoing measure of
inventory accuracy and procedure execution.
RF SCANNER

This Shows the

amount of the goods
model wise and also
shows us how for
how many products
the pick slip already
generated.
 This 6 pictures
shows the most
used features of
the RF Scanner.
The Load No. and
Customer are
gathered from
scanning pick slip.
How to create Logistics Code

 Logistics Code:
Last 5 digit of Product Code in EAN-13 (exclude check digit)+ First 3 Digit of SL No. (Year & Month)+ Last 6
Digit of SL No. + Product Suffix(7 Alphabet).
 Production Plants/ CDC

Region Distribution Centre

Transportation

Durgapur Code AJE

Kolkata Code AIO

 Eastern RDC

Kolkata Durgapur

East & West

Howrah
LG’s Kolkata and Durgapur Branch caters to Burdwan

these respective regions

Kolkata
Murshidabad
Suburb

East & West

North Bengal
Midnapur

Both Durgapur and Kolkata Branch’s orders are Hooghly Nadia

dispatched from New Gopalpur
Warehouse(Kolkata). North & South
Sikkim
Paraganas

Andaman &
Bhutan
Nicobar
Inventory Management : Sub-Inventory
WAREHOUSE LAYOUT :
OLD NEW
Improvement after changing the Layout of the Kolkata W/H

 Create a wider Gangway in front of DOCK which provides ease to que the product before loading and
temporarily staging the product when it is Unloaded.
 Easier to Scan the products with Hand held RF Scanner and easy to access interior spaces of the
warehouse.
 At the rear end of the DOCK No 1 & 2 there was a long pallet location which was blocking space.
 2 gangways have been eliminated so the space efficiency increases.
 Total Number of pallets located currently are as follows-
Pallet Count 6 5 4 3 2 1 Total
No of Location 33 113 91 50 57 106 450

 Total Number of pallets are 1497 *2 = 2994 in Double stacking which is more than the previous layout
pallet count.
 Good 5S Maintenance due to less dust.
 Separate Area For Cage & NGSI Location.
 Good Floor quality.
 Wider Gangway helps to move Forklift truck and Stacker smoothly inside Warehouse space.
Material Handing Equipment in LG Warehouse

Forklift Truck Stacker Hand Pallet Truck Handcart

QUALITY
WAREHOUSE 5S CHECKLIST
MATERIAL HANDING INSTRUCTION LIST:
PANTOS Logistics 10+ ! No Policy

1 No Smoking Do not smoke in workplace

2 No Stepping Do Not step on products.
3 No Kicking Do not kick products out while handling.
4 No Receiving Do not receive products with defects.
5 No damaging Do not cause damages to products.
6 No Discrepancy Do not make discrepancy between real and system.
7 No Over Speed Observe speed limit.
8 No idle Time Comply with start, break and end time.
9 No Dust Keep products free out of dust.
10 No Humidity Keep warehouses, trucks, and containers dry.
11 No Dead Space Reduce empty space in trucks and containers.