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Process Mapping
As Is & Should be Processes
Fish Bone
Pareto Analysis
Vital Xs
Safety Stock Development at WHs
Safety Stock Calculation Format
Past Sales history (STDV)
Expected Demand during Lead time (EDDLT)
Service Level (SL)
Time Staggered Outlooks & Shipment Plans
OL & Shipment Plan Development--- WH wise
Monitoring of shipment plan--- WH wise
The Pilot Run
(July-Oct.2010)
Data Analysis & Benefits
The Pilot Run
Pilot Run -- Sahiwal, Okara and Lahore.
Warehouse-Wise Outlooks on Weekly were developed and a
Safety Stock Level was defined on Monthly basis
A time staggered shipment plan was finalized with Brands
and Distribution
Brands developed a Weekly Potato Monitoring Sheet
Coordination of Sales, Brands and Distribution was
maintained as per the pilot run SOPs
Warehouse Closing Inventory Data was monitored through
DSR
Warehouse-wise Sales and Inventory Trends were plotted
against the Safety Stock Levels
Consumption of Safety Stock was Calculated on Warehouse-
wise basis and Project Benefit was estimated
PILOT RUN DATA ANALYSIS 95% Service.xlsx
Project Benefits
Year Total Sales Lost Sales % Lost Sales
2009 (mt)
6704 (mt)
1100 (Y)
16
2010 8450 600 7
Sustainability:
Half Day Session with all AMMs of LHE &
FSD Zone
Concept of Safety Stock down the line.
Appendices
Defi
Defi Project Start Date : Project Ending Date : Team
ne
ne March 26th , 2010 Dec . 31 , 2010 NIq, AN, MSM, NIt, MJAK, AMd
Extended Team
RN, ASd,
Problem Statement :
In 2009, three marketing areas (Sahiwal, Okara & Lahore) observed major stock outs Scope
during peak potato season (July-Oct) in Zarkhez green. This resulted into a lost Include :
sales of 1100MT which is 16% of total sales (6740MT) in these areas. It has also Potato crop (July to Oct)
been supported through market research (2008 conducted in OKA) that 25% of Non- Sahiwal, Okara, Lahore areas
user farmers segment (41% of total population) and 21% of the Lapse farmer Inventory management at
segment (29% of total potato growers) are switching from Zarkhez due to product warehouses
unavailability. This resulted in loss of Rs: 3.6 million in CM. Zkz Production plan for this
time frame
02/03 plant orders
Project Goal Statement : Zkz Outlook accuracy
1)To reduce the %age of Lost Sales w.r.t .Total Sales to 5%
2)Develop a process for inventory management at warehouses.
Exclude :
§Import decision
§Phosphate & Zkz market
dynamics
§Shipment lead time
Business Case :
Due to stock outs, there were sales lost of 1100 MT of Zarkhez Green during July-
Oct (that is 16% of total Zarkhez Green sold in these three areas for the
mentioned period in 2009). By inventory management at warehouses we can reduce
the lost sales % to 5%., which would result in improved revenue generation for
the company.
Projected Benefits :
Customers
Internal: North Sales Department To reduce the lost sales to
External: Farmers, Dealers 5% (CM: Rs. 2 M)
Develop a process for
inventory management at
CTQ ’ s : warehouses.
Inventory Management; Product Availability at Whs (Must have) Increase in revenue by the
Increase Sales/Revenue/Reduce Stock outs reduction in sale-lost.
Part/full processes from this
project can be replicated for
other crops as well.
Meas
Meas
ure
ure
Tool Usage : Notes / Graphs :