Skills & Expertise

An enhanced version of 5S emphasizing workplace safety.

• Sort: Remove unnecessary items.
• Set in Order: Organize tools and materials for easy access.
• Shine: Maintain cleanliness regularly.
• Standardize: Establish uniform procedures.
• Sustain: Foster discipline to maintain standards.
• Safety: Ensure a hazard-free work environment.
  Use Case: Warehouse layout optimization and daily operations management.

A structured approach to analyze problems or situations deeply.

• Who is involved?
• What happened?
• When did it happen?
• Where did it happen?
• Why did it happen?
• How did it happen?

Purpose: Useful for root cause analysis, planning, and comprehensive reporting.

 Identifying and eliminating non-value-added activities improves efficiency.

1. Defects
2. Overproduction
3. Waiting
4. Non-utilized talent
5. Transportation
6. Inventory excess
7. Motion
8. Extra processing
   Purpose: Streamline operations by reducing waste.

• A Japanese term meaning "change for the better" or "continuous improvement".
• Small improvements made regularly by everyone.
• Emphasis on teamwork, discipline, and morale.

Purpose: Incremental and continuous improvements in all functions of an organization.

 A continuous improvement cycle.

• Plan         – Identify and analyze the problem.
• Do            – Implement the solution.
• Check      – Evaluate the results.
• Act           – Standardize the solution or adjust and repeat.

Purpose: Systematic approach for process improvement.

 Inventory classification technique based on value and usage frequency:

• A     – High-value, low-quantity items (tight control)
• B     – Moderate value and volume (moderate control)
• C     – Low-value, high-volume items (simple control)

Purpose: Focus resources on high-value inventory for better cost control.

Just-in-Time (JIT) is a smart inventory method where materials or products are received only when needed — not stored in advance.

This helps companies:

• Save storage space
• Reduce waste
• Cut down extra costs

Example:
A factory gets parts only when it’s ready to use them — not weeks before. This avoids overstock and keeps operations smooth.

Meaning: The oldest items are used or sold first.

Example: Imagine you have milk cartons in your fridge. You drink the one you bought first before the newer ones. This way, nothing goes bad.

Usage: Common in inventory management to keep products fresh and avoid spoilage.

Meaning: The newest items are used or sold first.

Example: Imagine stacking plates. You take the top (most recent) plate first, not the ones at the bottom.

Usage: Sometimes used in accounting or specific industries where recent costs are matched with current sales.

Scoring based on:

• Quality
• Price
• Delivery
• Compliance

Use in Work: Conducted quarterly review of vendor scorecard.

From PR to Payment:

• Purchase      Request
• Quotation
• PO
• Delivery
• Invoice
• Payment

Use in Work: Ensured smooth workflow using ERP automation.

What is 3PL?
3PL means outsourcing your logistics and supply chain tasks to an outside company.

What do they do?
They handle services like warehousing, transportation, inventory management, and order fulfilment for you.

Why use 3PL?

• Save      time and money
• Access      expert logistics services
• Focus      on your core business while they manage shipping and storage

• RFI    :      Gather preliminary supplier info.
• RFQ  :      Get pricing.
• RFP  :      Get complete proposal for projects.

Use in Work: Used during vendor finalization and strategic sourcing.

What is it?
Demand forecasting is predicting how much of a product customers will want in the future.

Why it’s important:

• Helps      plan how much to produce or buy
• Avoids      running out of stock
• Prevents      excess inventory and wasted money

How it works:
By studying past sales data, market trends, and other factors, businesses estimate future demand to make better decisions.

What are SOPs?
SOPs are step-by-step instructions that explain how to do a specific task or process correctly and consistently.

Why use SOPs?

• Ensure      quality and consistency
• Help      new employees learn quickly
• Reduce      errors and improve safety

How it works:
Everyone follows the same clear steps to complete tasks, so work is efficient and reliable.

What is it?
MRP is a system that helps businesses plan and buy the right amount of materials needed to make products, at the right time.

Why it’s important:

• Avoids      running out of materials
• Prevents      excess stock
• Helps      meet customer demand on time

How it works:
MRP looks at what products you need to make, checks current inventory, and calculates what materials to order and when.

What is it?
It’s the smart way of arranging products in a warehouse to make picking and storing faster and easier.

Why it matters:

• Saves      time finding items
• Reduces      worker effort
• Improves      overall warehouse efficiency

How it works:
Frequently sold items are placed in easy-to-reach spots, while less popular items are stored farther away.

What is it?
Stock Reconciliation means checking your actual inventory to make sure it matches the records.

Cycle Counting:
Instead of counting all stock at once, you count small portions regularly (daily, weekly, or monthly).

Why do it?

• To      find and fix errors early
• To      keep inventory records accurate
• To      avoid big surprises at the end of the year

How it works:
You count a selected part of your stock, compare it with what your system says, and correct any differences.

What is it?
It tells you how many times you sell and replace your stock in a certain time (like a year).

Why care?

• High      number = You sell products fast, so less money stuck in inventory.
• Low      number = Stock is sitting too long, which may cause problems.

How to calculate:
Divide the cost of what you sold by the average stock you had.

Formula:
Inventory Turnover Ratio = Cost of Goods Sold ÷ Average Inventory

Simple example:

• You      sold goods worth ₹1,00,000 this year.
• Your      average stock was ₹20,000.
• Inventory      Turnover Ratio = 1,00,000 ÷ 20,000 = 5 times.
      This means you sold and restocked your inventory 5 times in the year.

The Kanban System is a visual way to manage work and inventory. It uses cards or boards to show tasks or materials moving through steps like:

To Do → In Progress → Done

It helps teams:

• See      work clearly
• Avoid      overload
• Improve      workflow

Example:
A team uses a board with sticky notes to track tasks. When one task is done, the next one starts — keeping work smooth and steady.

What is it?
Pareto Analysis says that 80% of results come from 20% of causes.

• 80% of your total spending may come from 20% of your suppliers. 
• 80% of problems (like late deliveries) may come from 20% of vendors.
   

In Warehouse:

• 80% of your inventory value may come from just 20% of items. 
• 80% of picking happens from 20% of frequently used products.
   

• To focus on what matters most. 
• To solve the biggest issues first.
• To reduce waste and improve performance.

What is it?
Six Sigma is used to solve problems, reduce mistakes, and improve quality in work.

It follows 5 simple steps:
Define → Measure → Analyze → Improve → Control (DMAIC)

Why Use Six Sigma?

• Fewer mistakes in purchasing and storing items
• Faster work process
• Better supplier performance
• Improved inventory accuracy
• Improves customer satisfaction
• Reduces waste and delays
• Makes processes faster and more accurate
• Supports continuous improvement culture