Plant Logistics Management System (PLMS)

Solutions to Excel

High plant turnaround

times (GIGO)

High yard waiting time

Safety issues within the

plant

Efficiency at Packer

(Productivity)

MIS to track different

KPIsHigh

dependency on people

Long & variable

transit times

Operational Challenges at Plant Site

What is THE Business Goal?

Primary

Tracking the KPIs with regards to Inbound / Outbound process management to improve productivity / plant process efficiency

Implementing Controls and Checks around Logistics Operations

Weigh Bridge Automation / integration to reduce Theft and Plant in-time for vehicles

Run Time Production counting for Outbound Process Improve the Packer efficiency Automatic MRP Printing on Bags to remove manual errors Controlling Busted g Bags and Increase Plant ‘s Dispatch

Secondary

Minimize paperwork and dependency on people Improve plant safety Improve service level to customers

What Needs To Be Done

Process Improvement

Security Entry

Process

Delivery Order

Process

Weigh-bridge Process

Bag Counting Process

Bag Printing Process

Integration – Industrial Process + Application

Reduced Vehicles TAT• Reduce TAT Inside the Plant• Reduce Yard Waiting Time• Reduce Plant Waiting Time

Improve Plant Safety• Control Movement of Vehicles within Plant• Minimize People Dependency and Paper

Transactions

Automation& Productivity

• Align Dispatches with Order Requirements• Sequence Entry of Vehicles into Plant• RFID Based Tracking of Vehicles• Automation at Packer, Weigh Bride, Loading

Points & Gates• Improved MIS

Benefits

Amazin Solution - PLMS

Gate –In StageYard StageWeighbridge Stages

Higher safety and Less

Dependency on Human

Can be easily integrated with ERP

Automation

Low Yard TimeLow TATHigher Loading utilization

Control & analyticsAutomatic DO and IGP is Created as soon as vehicle enters into yard

More Visibility over vehicles at yard and Plant.

Sequencing is done based onVehicle arrival timing in Yard & Product type

Alerts and reports for Unauthorized Vehicles

Components of Proposed Solution

Hardware Layer UHF RFID readers and tags, GPS, LED display, Signaling systems, boom barriers & PA system

Middleware• Integration with packer & bulk loader PLC.• Integration with weighbridge, bag / bottle / boxes counters, MRP printers etc.• Integration with ERP (SAP) and other transaction systems

Transaction system Yard, weighbridge, gate, loading & unloading point transaction, Production Counting, MRP Printing recording

AnalyticsReal time analysis and Dashboards

ReportingUser defined Management and Operational Reports

Optimization layerFleet scheduling and queuing logic

Collaboration layerTransporter collaboration and reporting

Extension frameworkUser defined stages, events and alerts to address specific needs

What Will This Do ?

■ Real time control and visibility into all major activities within the plant■ Sophisticated scheduling ensures best possible schedule for trucks and

packers ■ Scheduling generated the truck entry sequence■ Queuing ensures trucks enter as per plan■ Immediate re-plan whenever something goes wrong■ Give visibility to drivers and transporters on upcoming requirements

Helps the larger community■ Synchronized movement will lead to lower lost time, lower logistics cost

and higher service level■ Planning of operations■ Move beyond simple automation to a more proactive approach

How This Will Help ?

■ In plant turnaround time will be decreased 30-90 mins■ Average yard waiting time will be decreased 2-3 hours■ Loading utilization will be above 90-95%■ Customer service (on time delivery) of 80-90%■ No manual Entry Gate Check-In■ LED Displays at weighbridge, loader and yard to guide the drivers

without human intervention■ Packer and CDS dashboard will show the continuous progress of

loading statistics■ Reduce accidents in the plant■ Fewer manpower requirements for supervision, communication etc.

Business Benefits

■ Increase the no of Trips by 20-25% ■ Reduced Yard detention and In-plant TAT by 4 - 5hrs (500 trucks/day

saving is 2000 to 2500hrs■ More ROI for transporters (30%)and bargaining power for the plant

management.■ Dispatches can be managed with reduced fleet – Reduced logistics

costs.■ Minimal man power needs and elimination of unnecessary paper

transactions –entire dispatch system is automated from – yard in to plant out.

■ Packer optimization to increase productivity throughput.■ Enhanced customer satisfaction.

Sample Business Case

Activity Before Solution

After Solution

(estimated )

Benefit

1 In plant TAT 2-3hrs 1hr Saving of 1hr

2 Yard Detentions 5-6hrs 2-2.5hr Saving of 3-4hrs

3 Total Time savings 4-5hrs4 Plant out to (cust) to

Yard In12hrs

(assumed)5 % of dispatches

increased by20-25%

Conclusion

Because you should be relaxing as our Customer DO