Improving Warehouse Performance Control (SAP + Excel)

Context

The organization lacked a reliable and measurable way to monitor warehouse performance. Employee efficiency was assessed mainly through observations and subjective opinions, without support from system-based data.

Problem

• Lack of consistent data related to completed warehouse activities
• No clear and structured reports for management
• Difficulty identifying inefficiencies and operational bottlenecks

Solution

• Extracted operational data from SAP covering all warehouse processes
• Converted and structured the data in Excel to ensure clarity and usability
• Developed weekly performance reports reflecting actual employee productivity
• Implemented regular reporting of results to management

Outcome

• Introduced reliable and measurable control of warehouse performance
• Increased transparency of operational processes
• Enabled data-driven decision-making instead of subjective assessments
• Faster identification of inefficiencies and process bottlenecks
• Improved communication between warehouse operations and management

Optimization of Warehouse Packaging Management

Context

The management of corrugated cardboard packaging was conducted without data analysis or regular inventory control, leading to excess stock, warehouse disorganization, and operational issues.

Problem

• Packaging orders placed without data-driven justification
• No cyclical inventory control of packaging materials
• Warehouse overcrowding and lack of available space
• Discrepancies between physical stock and system records

Solution

• Reorganized the packaging storage area to improve accessibility and order
• Aligned physical stock levels with system data (SAP)
• Changed the ordering model from monthly bulk orders to demand-based ordering
• Defined lead times with suppliers
• Introduced daily stock monitoring and ordering based strictly on system data

Outcome

• Reduced time spent by warehouse staff searching for packaging
• Improved utilization of warehouse space
• Eliminated capital tied up in excess packaging inventory
• Prevented losses related to leftover packaging after project closures
• Created a stable, predictable, and data-driven packaging management process

Improvement of Batch Traceability in SAP

Context

Despite using SAP, the repackaging process and production returns caused inconsistencies in batch data, leading to issues with complaints handling and product history analysis.

Problem

• Incorrect batch assignment during repackaging
• Production returns received under different batch numbers
• Inability to fully trace product history in SAP

Solution

• Conducted training sessions for warehouse employees involved in repackaging
• Standardized the rule that batch numbers remain unchanged from receipt to consumption
• Took ownership of the production returns process
• Organized and standardized system processes in SAP

Outcome

• Improved data quality in the SAP system
• Full batch traceability throughout the product lifecycle
• More efficient and reliable complaints handling
• Increased trust in system data
• Reduction of operational errors