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Kaizen 3

The document outlines various solutions to improve inventory management and warehouse efficiency using SAP EWM. Key improvements include automated reconciliation, optimized slotting, and enhanced picking processes, which collectively reduce operational delays and improve productivity. Each solution is accompanied by specific problems, benefits, and visuals to illustrate the proposed changes.

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Amit Saxena
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13 views4 pages

Kaizen 3

The document outlines various solutions to improve inventory management and warehouse efficiency using SAP EWM. Key improvements include automated reconciliation, optimized slotting, and enhanced picking processes, which collectively reduce operational delays and improve productivity. Each solution is accompanied by specific problems, benefits, and visuals to illustrate the proposed changes.

Uploaded by

Amit Saxena
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
Available Formats
Download as DOCX, PDF, TXT or read online on Scribd
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Slide 3: Automated Reconciliation

Problem: Manual reconciliation delays with system stock vs. physical stock
mismatches.
Solution:
 Configure SAP EWM for automated comparison of system and physical
inventory.
 Set up error alerts for discrepancies.
Benefits:
 Reduces reconciliation time by 70%.
 Improves trust in inventory data.
Visuals: Workflow showing automated reconciliation steps.

Slide 4: Slotting Process Improvement


Problem: Inefficient picking due to poor product placement in bins.
Solution:
 Use SAP EWM’s slotting to classify products as fast-moving, medium, or
slow-moving, and rearrange them.
Benefits:
 Reduces picking times by up to 30%.
 Enhances worker productivity.
Visuals: Heatmap of a warehouse showing fast-moving items closer to picking
zones.

Slide 5: Handling Inventory Blockages


Problem: Stock stuck in “Blocked” or “Quality Inspection” areas.
Solution:
 Automate workflows to monitor and release blocked stock.
 Train workers to trigger automated processes in EWM.
Benefits:
 Speeds up inventory turnover.
 Avoids delays in fulfilling orders.
Visuals: Process flow of blocked stock release.
Category 2: Picking and Packing Efficiency
Slide 6: Wave Picking Optimization
Problem: Inefficient picking for high order volumes.
Solution:
 Use wave templates in EWM to consolidate orders based on time, route, or
product type.
Benefits:
 Reduces picker travel time by 25%.
 Allows grouping of similar orders.
Visuals: Diagram of wave picking logic in SAP EWM.

Slide 7: Pick Denial Management


Problem: Delays in resolving out-of-stock situations during picking.
Solution:
 Configure pick denial processes to trigger alternatives or backorder
notifications.
Benefits:
 Reduces order delays.
 Enhances customer satisfaction.
Visuals: Screenshot of a pick denial workflow in SAP EWM.

Slide 8: Pick Path Optimization


Problem: Long travel distances for pickers in large warehouses.
Solution:
 Optimize picking paths dynamically based on product demand and bin
locations.
Benefits:
 Increases pick rates by 15-20%.
 Reduces worker fatigue.
Visuals: Illustration of optimized picking paths (zigzag vs. optimized).

Slide 9: Packing Station Process Streamlining


Problem: Errors in packaging instructions for fragile or special items.
Solution:
 Introduce packing instructions in SAP EWM for specific items.
Benefits:
 Ensures consistent packaging.
 Reduces damaged goods claims by 20%.
Visuals: A checklist for packing fragile goods in EWM.

Category 3: Receiving and Putaway Process


Slide 10: Dock Door Scheduling Automation
Problem: Congestion at dock doors during peak hours.
Solution:
 Use SAP EWM yard management to dynamically assign dock doors based
on truck arrival.
Benefits:
 Reduces unloading delays.
 Enhances dock door utilization by 30%.
Visuals: Timeline showing scheduled vs. unscheduled dock usage.

Slide 11: Guided Putaway


Problem: Inefficient use of storage space due to random putaway.
Solution:
 Use guided putaway rules to assign storage bins based on size, velocity,
and temperature requirements.
Benefits:
 Improves space utilization by 20%.
 Speeds up putaway time.
Visuals: Decision tree for guided putaway in EWM.

Slide 12: Cross-Docking Opportunities


Problem: Delays in storage for frequently transferred items.
Solution:
 Set up cross-docking to move goods directly from receiving to outbound
staging.
Benefits:
 Reduces storage costs.
 Speeds up delivery.
Visuals: Flowchart of a cross-docking process.

Category 4: Labor and Resource Management

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