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Contents
Audit Information
Storage equipment
Handling equipment
Inventory management
General warehouse
Summary
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Audit Information
What’s in the report:
The audit provides a comprehensive assessment of your facility, along with date/time stamped photographic evidence.
Comments/Recommendations and Corrective actions can be noted to show where improvements can be made.
Management reports:
This is a separate report that shows the previous audits KPI scores and compares these to the current KPI score.
This clearly shows the increase or decrease KPI score, when issues have been addressed.
Colour coded corrective actions show which have been completed and which are still outstanding.
Along with the previous and latest date/time stamped photos.
The management report can be Referenced to historical reports, to show previous data, so you can measure improvements over a long period.
The Warehouse Auditor app has been awarded UKWA ‘technical innovation of the year’ 2016.
Contact
Sales: enquiries@warehouseauditor.com
Support: support@warehouseauditor.com
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Utilisation of warehouse capacity
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REF: 1.1 REF: 1.1 REF: 1.1
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REF: 1.3 REF: 1.4 REF: 1.4
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REF: 1.6 REF: 1.6 REF: 1.6
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Summary
Corrective Action
Ref Action Priority
1.1 Stock and items stored at ends of racking aisles needs to be removed and stored in appropriate location
1.2 Lights above racking need to be relocated
1.3 Review of locations required to accommodate over-sized pallets
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Control of warehouse processes
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Ref Question Answer Comment
2.11.1 Is the process effective? Mixed SOP's cover this aspect of operations.
2.12 Despatch Yes
2.12.1 Is the process effective? Effective
2.13 Returns (RMA) Yes
2.13.1 Is the process effective? Mixed Further improvement required. Returns management needs to be completed
daily to ensue that any damages are managed accordingly.
2.14 Value Added Services Yes
2.14.1 Is the process effective? Mixed Rate cards used to cover individual customer requirments.
Re-labelling operations are provided as required.
2.15 Other (describe) Yes Iso 9001/2008 and Iso14001 compliant.
2.15.1 Is the process effective? Effective
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REF: 2.12 REF: 2.13 REF: 2.14.1
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REF: 2.16
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Summary
Corrective Action
Ref Action Priority
2.1 Consider rolling out WMS for all warehouse operations
2.1.1 Appropriate for main client with use of RF technology.
2.2 Training matrix for each operative. Review process every six months
2.3 Consideration should be given for further management training of team leaders
2.4 Staffing levels to be managed based on delivery schedule for main customer
2.5 Creation of a deliveries due report, will assist in daily capacity requirements
2.7 Used system in place, recommend locations for put away operation
2.8 Use information from WMS to optimise replenishing
2.9 Allocation of customer batch requirements
2.11 Good utilisation of outbound marshalling area
2.12 Out-bound marshalling area for courier despatch
2.13 RMA placed into cages for final sortation to stock or disposal
2.13.1 Returned items should be managed on a daily basis as opposed to the current process
2.14.1 Mixed services repackaging labelling and kitting
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Storage equipment
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REF: 3.14 REF: 3.13
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Summary
Corrective Action
Ref Action Priority
3.13 Annual SEMA inspection to be arranged.
3.15 Programme of regular inspection required for reporting and corrective actions for any damaged storage equipment.
3.16 Please refer to comment in section 3.15
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Handling equipment
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Summary
Corrective Action
Ref Action Priority
4.1.2 Operating hours need to be recorded against actual work hours to ensure correct maintenance and support are provided.
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Inventory management
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Summary
Corrective Action
Ref Action Priority
5.1 Operational programme required for PI using WMS
5.2 Observation: Classification used for 70% of operations
5.4 Observation: Target levels are Customer driven.
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General warehouse
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REF: 6.5 REF: 6.8 REF: 6.8
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Summary
Corrective Action
Ref Action Priority
6.2 Floor markings need to be re-established for marshalling areas and main pedestrian routes.
6.3 Refresher training required for all operatives
6.4 Warehouse audits carried out internally. Part of SOPs will assist with housekeeping
6.5 Review SOP's covering this operational aspect
6.6 Consideration to be given for areas to be clearly defined and marked
6.7 Consideration to be given for areas to be clearly defined and marked
6.8 Use housekeeping audit documents provided with SOP's
Knife policy to be compiled and all operatives trained on safe use.
6.9 Consideration needs to be given for a strategy document
6.10 Evidence to be provided
6.12 Third party service provider with continual backup
6.13 Restricted access via keypad. Warehouse doors opened during operating hours
6.14 Training of operatives using SOP's for vehicle marshalling.
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Cost and operational control
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Summary
Corrective Action
Ref Action Priority
7.1 Effective for 90% of customer base. Use KPI information for individual customers.
7.2 Operational hours to be compared to contract hours.
Review service contract to ensure correct service support levels and breakdown cover for extended work periods.
7.3 Consider using information from WMS system to record packing rates for operation for each customer.
7.4 Optima used for main customers. CRM for all other customers.
Returns need to managed on a daily basis.
7.5 Optima system to be used for reporting for main customer. Account managers control all other service reporting and this needs to reported at
weekly service level meetings.
7.6 KPI,s need to established for all customers not covered by current WMS reports.
7.7.1 Budgeting of historical information and fore-casting from customer needs to be reported.
7.7.2 Costs for remaining customers need to be reported to provide full reporting costs to ensure effective budgeting.
7.7.3 Activity based costing
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Audit Summary
Overall Observations
The warehouse has an extensive and varied range of products and stock profiles which require a diverse number of stock location sizes including pallet racking, block
storage and shelving.
General condition of the warehouse is satisfactory but attention needs to be given to floor markings to assist in segregation of stock, pedestrians and FLT’s.
Storage for bulk and replenishment stocks are located randomly throughout the warehouse and should be located as close to pick faces as possible.
Operational staff have varying levels of awareness of the processes and procedures required to effectively manage the daily tasks.
All staff need to adhere to the procedures for safe movement throughout the warehouse and external yard areas.
Access to the main building is well controlled but external areas of the facility are not effectively secured or managed.
Control of key information is effectively managed using an effective IT and Warehouse Management system providing effective process control and accurate
information.
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Overall Recommendations
Attention needs to be given to implementing refresher training to ensure all staff are aware of the Standard Operating Procedures to optimise the processes and
procedures.
Stock stored on the floor and at end of racking aisle needs to be removed and stored in a suitable racking location to improve product integrity and security.
Pallet racking aisles and marshalling areas need to be kept free of debris to improve clear access to all locations and to prevent slips, trips and falls.
Procedures for recording damaged storage equipment required and effective corrective actions need to be put in place and records retained for future audits.
Implementation of annual SEMA storage equipment inspection required to ensure all racking and shelving is secure and Fit for Purpose.
Continuity policy & planning strategy needs to be put in place to highlight areas of service improvement.
Perpetual Inventory checks should be implemented to address stock queries and increase the accuracy of stock to circa 98%+ on an ongoing basis.
WMS storage parameters need to be amended to ensure the stock put-away, replenishment and location management process is optimised.
The Work Flow/Work Load information from the WMS needs to be used to provide detailed information for each operator and activity and to optimise all resources.
A schedule of regular audits needs to be implemented to ensure that the recommendations and corrective actions contained in this audit report are implemented and
maintained.
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Signatures
Auditor
Date: 15/01/2018
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