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Warehouse Safety Regional Challenges Presented by: XXXXXXXXXX Shailen Shukla Business Head Jumbo Logistics LLC Warehouse Safety and Automation RoundTable Shailen Shukla 31 May 2016 31 May 2016 Warehouse Safety and Automation


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31 May 2016

Warehouse Safety and Automation RoundTable

31 May 2016

Warehouse Safety and Automation RoundTable

Shailen Shukla

Warehouse Safety – Regional Challenges

Shailen Shukla Business Head Jumbo Logistics LLC

Presented by: XXXXXXXXXX

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31 May 2016

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31 May 2016

Warehouse Safety and Automation RoundTable

Shailen Shukla

About Jumbo Logistics Introduction- Jumbo Electronics is the foremost ‘Consumer Electronics’ distributor in the UAE with

exclusive distribution rights for certain brands, such as - Sony, Hisense, Brother, Ricoh, Lenovo, Lava, LG etc. Jumbo group was established in 1974 and since then it has grown leaps and bound to become the largest Electronics Retailer and Distributor of UAE. Jumbo Logistics is the logistics division of the Jumbo Electronics group. It has consolidated warehousing capacity >320K SFT across UAE, Oman , Kuwait and Qatar and employs >190 skilled manpower at its disposal.

Warehousing capacity- Jumbo Logistics has temperature controlled (Cold) and ambient warehouse

facilities and boasts of 300,000 SFT Warehouse space : 21,000 pallet positions : 18,000 shelving bins locations.

Warehouse Management System (WMS)- Jumbo logistics employs a truly world class WMS –

LFS(Logistics Focus Solutions) supplied by E+P, Germany. This WMS provides 100 % accurate and fast put- away, picking & loading with Serial no / EAN scanning and ensures Optimal WH space utilization with Real Time Inventory visibility and faster and accurate order fulfillment.

Logistics fleet- Jumbo Logistics owns 43 own vehicles (Nissan / Isuzu / Toyota) with GPS based tracking,

including 10 container beds, 6 forty feet containers and 3 prime movers and 11 tail lift vehicles. Jumbo fleet performs 40 Milk runs everyday touching up to 800 customers/day across UAE.

Awards & Accolades-

  • Average monthly ‘On time delivery performance’ 99% ( 0 -36 hours)
  • SCATA 2013 - Winner Supply Chain of the Year
  • SCATA 2014 - Supply Chain of the Year -Highly Commended
  • SCATA 2015 - Supply Chain Manager of The Year- Highly Commended Award
  • Valued partners award by Dubai customs
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31 May 2016

Warehouse Safety and Automation RoundTable

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JAFZA Warehouse, Dubai

Jumbo Warehousing Presence

  • Jumbo Logistics has been providing Low cost and Efficient Supply Chain solutions to JUMBO group for

past 40 years

  • ISO 9001 certified Warehousing capacity over 300K SFT (Jebel Ali – 230K; Jafza-50K; Abu Dhabi-20K)
  • Over 200 Skilled Manpower trained to use WMS / ERP systems
  • Consolidated Warehousing capacity >320K SFT across UAE, Oman , Kuwait and Qatar

115,000 SFT Jebel Ali Central Warehouse, Dubai

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20,000 SFT MINA Warehouse, Abu Dhabi

Jumbo Warehousing Presence

50,000 SFT JAFZA Warehouse, Dubai ISO 9001 Certified and Fully Equipped Warehouse Our People Our Strength

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Our Business Partners

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Warehouse Safety and Automation RoundTable

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Storage Solutions

  • Temperature controlled (Cold) and ambient warehouse
  • 300,000 SFT Warehouse space : 15,000 pallet positions : 12,000 shelving bins locations
  • Over 400,000 numbers- Monthly in-warded & dispatched
  • Put away accuracy 99.85% and Picking time - 30 Minutes to 60 minutes
  • High Security room -Du scratch card, phones and other high value items

Ambient pallet storage Temperature controlled Shelving Bins

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Warehouse Safety and Automation RoundTable

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Warehouse Management System (WMS)

  • World class WMS called LFS supplied by E+P, Germany.
  • Enables Optimal WH space utilization, “Real Time Inventory visibility” , faster and accurate order

fulfillment.

  • 100 % accurate and fast put-away, picking & loading with Serial no / EAN scanning
  • Infra Red Scan based operation- reduced paper / manual transactions and avoids time wastage
  • Scanning based operation helps faster/accurate order processing which results in efficient customer

deliveries leading to “Improved Client Relationships” which further leads to “Incremental Sales”.

RF devices based picking Mobile work-stations

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Delivery Solutions

  • 52 own vehicles (Nissan / Isuzu / Toyota) with GPS based tracking, including 10 container beds, 7 forty feet

containers and 5 prime movers and tail lift vehicles.

  • 40 Milk runs everyday touching up to 800 customers/day, RF scanning while loading.
  • State of the art vehicle maintenance facilities with the help of outsourced partners. Preventive rather than

breakdown maintenance to improve the efficiency.

JUMBO Logistics Fleet GPS vehicle tracking

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Milestones & Key Achievements

99.03% • On Time delivery performance – September 2015 30 to 60 Minut es

  • Extremely fast picking, 30 to 60 minutes to pick and load 1 full truckload

material

99.99% • Inventory Accuracy- Place for every item and Every item at its place 0.0001

%

  • Minimal shrinkages / discrepancies, 100 %Inventory traceability

SCATA

  • SCATA 2015 -Supply Chain Manager Of The Year- Highly Commended Award,
  • SCATA 2014 - Supply Chain of the Year -Highly Commended,
  • SCATA 2013- WINNER Supply Chain of the Year

VAS

  • Kitting , Bundling and Labelling to support events like Gitex, DSF & DSS.
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Awards & Accolades

SCATA AWARDS- 2014
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Worldwide Safety Standards

  • The Occupational Safety and Health

Administration (OSHA) is an agency

  • f the United States Department of

Labor. Congress established the agency under the Occupational Safety and Health Act, which President Richard M. Nixon signed into law on December 29, 1970. OSHA's mission is to "assure safe and healthful working conditions for working men and women by setting and enforcing standards and by providing training,

  • utreach,

education and assistance". The agency is also charged with enforcing a variety of whistleblower statutes and regulations.

  • The European Agency for Safety and

Health at Work (EU-OSHA) is a decentralised agency of the European Union with the task of collecting, analysing and disseminating relevant information that can serve the needs

  • f people involved in safety and health

at work. Set up in 1994 by Council Regulation (EC) No 2062/94 of 18 July 1994, EU-OSHA is based in Bilbao, Spain, where it has a staff

  • f
  • ccupational

safety and health, communication and administrative specialists.

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Regional Safety Standards

  • Abu Dhabi Civil Defence web

site has a page on “Safety In Warehouses” at the following link:

  • http://adcd.gov.ae/en/portal/s

tore.aspx

  • It

lists types

  • f

Fire Extinguishers and Usages

  • Pre operation instructions –

Manual Fire fighting equipments

  • Vision , Mission & Objectives
  • Violations that cause fires &

Increase their losses

  • UAE Fire and Safety Code Of

Practice a book of 707 pages dealing with fire safety.

  • Most of the detailed safety

rules and guidelines exist in Oil & Gas made by large

  • il

companies

  • Most of the countries have

detailed guidelines and instructions

  • n

fire safety management

  • Focus on warehouse safety

management has to be improved

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Heavy Equipment Accidents

  • 20,000 employees are injured, 100

fatally annually in USA in MHE accidents

  • 25%
  • f

incidents are caused by

  • verturning of forklifts
  • When employees work with warehouse

heavy equipment such as a forklift every day, they tend to get very comfortable using the equipment. This can be very dangerous if the operator begins to underestimate the danger of the machine.

  • Ensure that all employees understand

the potential hazards a forklift or other warehouse machines present and never get too comfortable. Remain cautious and careful when

  • perating

any

  • machine. Always follow the specific

instructions provided for the equipment and avoid situations where a forklift accident is likely.

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Prevention

Forklifts

  • Train,

evaluate, and certify all

  • perators & Forklifts. Overconfidence

is enemy number one !!!

  • Prohibit under / over age employees.
  • Train

employees to examine equipment for hazards before using.

  • Drive slow @5 miles per hour, and

slow down in congested areas. Beware of blind spots.

  • Maintain sufficiently safe clearances

for aisles. Habitual Offenders !!!

  • Train

employees

  • n

the hazards associated with combustion-related byproducts of forklift operation, such as carbon monoxide. Near Misses

Docks

  • Drive forklifts slowly on docks and

dock plates.

  • Secure plates and check to see if the

plate can safely support the load

  • Provide visual warnings near dock

edges.

  • Make sure ladders and stairs meet

safety specifications.

  • Provide

railings where people / forklifts may fall

  • Provide guard rail / bump / speed-

breaker on platform edges.

  • Trucks should have rear cameras /

sensors / mirrors

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Slips and Trips

  • Slipping is a very common warehouse

hazard that can be easily avoided. To prevent the majority of slips and trips in your warehouse, eliminate the following factors:

  • Loose material such as sawdust
  • Liquids
  • Unnecessary steps or ridges
  • Boxes from the floor
  • Dark areas
  • Implementing anti-slip floor tape is

essential for ensuring the safety of your warehouse.

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Falls

  • Falling accounts for a large majority of

workplace

  • accidents. You and your

employees are always at risk of falling, not just when working above ground

  • level. Slipping and falling is a common

cause

  • f

injury among warehouse employees.

  • When working around loading docks,

remember your training and stay aware

  • f your surroundings. Also, whenever

there is a large drop between floors, proper guard railing is essential. The comprehensive guide to warehouse guardrails explains why you need to guard rails and how to implement them.

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Fires

  • A

fire can jeopardize your entire warehouse, but this warehouse hazard is also among the most preventable accidents. Building permits, clearly marked exits, exit strategies, and fire extinguisher laws are all in place to prevent fires. Still, fires are very common and require constant prevention awareness. Things to avoid are:

  • Worn and exposed wires such as old

extension cords

  • Leaking flammable fluids and gasses
  • Running electrical cords under carpet
  • Lighters and match sticks used by

smokers

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Crushed

  • According to the OSHA weekly

fatality / catastrophe report, two workers are crushed to death every month in USA on the job. Provide sufficient training for any machine with augers

  • r

press machines. Avoid moving machines and trucks in the loading dock. Also, be weary

  • f

heavy materials that could fall on your employees.

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Exposure to Harmful Substances

  • Harsh

chemicals such as asbestos and gases are a serious workplace hazard. Any employee that feels that their working conditions are not adequate can flag your warehouse for

  • inspection. Always ensure

that your employees are being taken care of.

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Ergonomics

  • Every warehouse employee must

take care

  • f

their bodies. Constant mistreatment will lead to pain and injury. There are several ergonomic solutions to common warehouse problems such as back and foot pain.

  • Make sure employees understand

the importance of proper lifting techniques.

  • It’s mandatory to wear helmets,

safety shoes, fluorescent jackets, etc.

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Moving Parts

  • Always

pay attention to warning labels. Machines with moving parts are a common workplace hazard. When used improperly, a machine can cause severe permanent injury and death.

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Prevention

Do’s

  • DO keep clothing, body parts,

and hair away from the conveyor

  • DO know location and function
  • f stop/start controls
  • DO ensure all personnel are

clear of equipment before starting

  • DO allow authorized personnel

to operate/maintain material handling equipment

  • DO make conveyor safety

training a priority

Dont’s

  • DON’T remove or alter

conveyor guards or safety divides

  • DON’T climb, step, sit, or stand

the conveyor at any time

  • DON’T perform service on a

conveyor until motor disconnect is locked out

  • DON’T modify or misuse

conveyor controls

  • DON’T fail to report all unsafe

conditions to your supervisor:

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Falling Objects

  • A common material

handling practice is stacking

  • bjects on high platforms

and shelves.

  • Always keep heavy loads

stacked neatly to avoid a shifting load or cylindrical

  • bjects from rolling off of

shelves.

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Prevention

Material Storage

  • Stack

loads straight and evenly.

  • Place

heavier loads

  • n

lower or middle shelves.

  • Train employees to remove
  • ne object at a time from

shelves.

  • Keep

aisles and passageways clear and in good repair. Manual lifting / handling

  • Provide

ergonomics awareness training.

  • Train

workers in proper lifting.

  • Minimize the need for lifting

by using engineering controls, adjusting work practices, and providing hand trucks and

  • ther

material handling aids.

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Lack of Safety Education

  • Without proper education, a

warehouse will not perform at its full potential. Many warehouses choose to skip thorough training to save money. This practice is unwise and will result in workers compensation lawsuits or OSHA fines.

  • A safe warehouse is an efficient
  • warehouse. Avoiding proper

training is the number one cause of workplace injury. Implementing a systems like 5S is the best way to instill a safe environment for your employees.

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Prevention

Hazard Communication

  • Maintain a safety data sheet

for each hazardous chemical to which workers are exposed.

  • Train employees on the risks of

all stored chemicals.

  • Provide spill cleanup kits.
  • Develop

and implement a written spill control plan.

  • Store

chemicals safely and securely, away from forklift traffic areas.

Prevent Personal Injuries

  • Adjusting

the height

  • f

shelves.

  • Providing stools or ladders to

employees.

  • Reducing

the depth

  • f

shelving.

  • Raising loading heights.
  • Evaluating

the flow and volume

  • f
  • rders

so that faster-moving products were placed

  • n

more accessible shelves.

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Warehouse Automation

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Smart SCM

  • Supply chain control:

Monitoring of storage conditions along the supply chain and product tracking for traceability purposes.

  • NFC payment: Payment

processing based in location

  • r activity duration for

public transport, gyms, theme parks, etc.

  • Intelligent shopping

applications: Getting advices in the point of sale according to customer habits, preferences, presence of allergic components for them or expiring dates.

  • Smart product management

Control of rotation of products in shelves and warehouses to automate restocking processes.

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IoT in Logistics

  • Quality of shipment

conditions: Monitoring of vibrations, strokes, container openings or cold chain maintenance for insurance purposes. Item location: Search of individual items in big surfaces like warehouses or harbours.

  • Storage incompatibility

detection: Warning emission on containers storing inflammable goods closed to others containing explosive material.

  • Fleet tracking: Control of

routes followed for delicate goods like medical drugs, jewels or dangerous merchandises.

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Industrial Control Automation

  • M2M applications: Machine

auto-diagnosis and assets control.

  • Indoor air quality: Monitoring
  • f toxic gas and oxygen levels

inside chemical plants to ensure workers and goods safety.

  • Temperature monitoring:

Control of temperature inside industrial and medical fridges with sensitive merchandise.

  • Ozone presence: Monitoring
  • f ozone levels during the

drying meat process in food factories.

  • 36. Indoor location: Asset

indoor location by using active (ZigBee) and passive tags (RFID/NFC).

  • 37. Vehicle auto-diagnosis:

Information collection from CanBus to send real time alarms to emergencies or provide advice to drivers.

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Smart Agriculture

  • Wine quality enhancing:

Monitoring soil moisture and trunk diameter in vineyards to control the amount of sugar in grapes and grapevine health.

  • Green houses: Control micro-

climate conditions to maximize the production of fruits and vegetables and its quality.

  • Golf courses: Selective

irrigation in dry zones to reduce the water resources required in the green.

  • Meteorological station

network: Study of weather conditions in fields to forecast ice formation, rain, drought, snow or wind changes.

  • Compost: Control of humidity

and temperature levels in alfalfa, hay, straw, etc. to prevent fungus and other microbial contaminants.

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Domotic and Warehouse Automation

  • Energy

and water use: Energy and water supply consumption monitoring to

  • btain advice on how to

save cost and resources.

  • Remote control appliances:

Switching

  • n

and

  • ff

remotely appliances to avoid accidents and save energy.

  • Intrusion detection systems:

Detection of shutters and doors

  • penings

and violations to prevent intruders.

  • Art and goods preservation:

Monitoring

  • f

conditions inside museums and art warehouses.

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Impact of Internet of Things (IoT)

  • ver Supply Chain and Logistics
  • Having the capability to track

raw or finished materials and the associated features such as count, type and geographical data with the Internet of Things technology through an entire life cycle from a tier-n supplier to the final consumer will have a positive influence on inventory management, sourcing strategies and logistics costs

  • The decision-making capacity
  • f smart devices within an IoT

enabled supply chain network affects the overall supply chain structure. Traditional supply chain tasks in procurement, supplier management, supply chain planning and logistics is streamlined by intelligent, data-driven systems in a collaborative multi-enterprise environment.

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Supply Chain Planning

  • IoT can be used to sense demand

for finished product by using embedded intelligent devices. IoT will enable the supply chain to automatically track available finished product across multiple distribution centres with sales channels indicating current demand. If no inventory is currently available, the system can check raw material availability and manufacturing capacity, leading it to send an automatic production trigger to the appropriate entity.

  • Further

up the supply chain, companies like Siemens will sell you software that sits in your manufacturing test stations. This software will send real time test results, per component, to a central system that looks for patterns that would indicate a human operator is "cheating" a component through the

  • test. Things like retesting (which can

expose the component to more heat than is recommended)

  • r

an excessive build up of a bone pile (where components are scrapped after failures, sticking the manufacturer with the cost).

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Supply Chain Sourcing

  • When

a supplier cannot deliver on time, that event could trigger an automatic search for an alternate supplier within the interconnected intelligent

  • system. This would ensure

no disruption in the production schedule, customer service

  • r

revenue stream.

  • It can also tell a manufacturer

when their overseas line is shut down (for some holiday,

  • r

just because everybody thought it was a good day to go to the beach). All of these things can allow a brand to have more control

  • ver

a component

  • r

even

  • utsourced

final assembly manufacturer. This control means less risk

  • f

bad products, of lost batches, and ultimately of sunk cost.

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IoT – Warehousing

  • In one of the latest initiatives to

get its own supply chain fully wired, Cisco has been installing thousands of sensors in a plant in Malaysia to monitor and reduce energy consumption. Mr. Kern said in an interview with The Wall Street Journal that the team leading the project believes that implementing the system throughout Cisco’s worldwide production sites will help reduce energy consumption by 20% to 30%, translating into tens of millions of dollars in cost savings.

  • Cisco has been looking at broader

supply chains as a part of its efforts to spread the idea of Internet of Things, the term for the web-enabled connections that can allow devices to transmit information about such things as energy consumption or

  • productivity. Cisco’s Consulting

Services group, for instance, is working with logistics provider DHL on a project to send real- time data on warehouse

  • perations, for instance.
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Supply Chain Manufacturing

  • Factory
  • f

the Future

  • r

Smart Manufacturing is getting popular across manufacturing industries which means usage of advanced technologies, usage

  • f internet of things and applying

analytics data to make manufacturing more productive and responsive.

  • IoT enabled factory equipment and

manufacturing units will be able to transmit temperature and machine utilization parameters, change equipment settings and

  • ptimize

process workflows. IoT devices will be able to generate alerts on lifetime expiration dates and maintenance to increase

  • verall

supply chain performance and efficiency.

  • IoT is also helping the food processing and

manufacturing sector by continuous monitoring of factory climate conditions and detection of the presence of allergens.

  • Used to be that there mighy be a rep from a

manufacturer there when you delivered, now there's a Wi-Fi chip in a test unit sending back data in real time to a dude at Apple who contracted a manufacturer who contracted a supplier who has the relationship with the material shop that's like, working with

  • miners. And this Apple dude is giving the

thumbs up to the purity of the material like

  • Mr. White was judging the quality of the Blue

Ice in Breaking Bad.

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Logistics

  • IoT can manage stock in a warehouse and

distribution centres with automatic inventory flow and control mechanism to reduce out-

  • f-stock situations. IoT is also being used in

identifying wastes and implementing waste reduction techniques.

  • Key to in-transit visibility is cloud-based GPS

and Radio Frequency Identification (RFID) technologies, which provide identity, location, and other tracking information. Fleet management solutions are utilizing the technologies to save fuel costs, optimize fleet routes by monitoring traffic conditions. Data gathered from GPS and RFID technologies not only allows automation of shipping and delivery by exactly predicting the time of arrival.

  • By tapping the data gathered by these

technologies, detailed visibility of an item is provided all the way from the manufacturer to the retailer.

  • According to the Food and Agriculture

Organization of the United Nations, about one third of food perishes in transit every year. The cold chain industry is also getting the benefits of IoT to ensure temperature stability which impact the quality of a product in-transit.

  • Embedded sensors in products provide

visibility into customer behaviour and product usage.

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Supply Chain Solutions leveraging Technologies

  • End users are interested in

using IoT technologies to manage accurate and transparent shipment tracking;

  • Business users and supply

chain partners are interested in integrity control for sensitive and valuable goods;

  • Logistics

companies need transparency over distribution networks, network utilization and tracking assets being used for optimization of efficiency;

  • IoT need to be used to create

a highly transparent and integrated controller which will help to identify the right product, at right time, at right place, in right quantity and condition and with right cost.

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IoT Cold Chain

  • Ensure

temperature

  • stability. Monitor the cold

chain – according to the Food and Agriculture Organization of the United Nations, about one third of food perishes in transit every year.

  • Manage warehouse stock.

Monitor inventory to reduce

  • ut-of-stock situations.
  • Gain user insight. Embedded

sensors provide visibility into customer behavior and product usage.

  • Create

fleet efficiencies. Reduce redundancies – deadhead miles account for up to 10 percent of truck miles, according to the EPA, and 28 percent for private fleet trucks, according to the National Private Truck Council.

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IoT In Logistics – The Internet-Connected Engine Will Change Trucking

  • It’s happened to all of us. You’re driving down the road and the

“check engine” light appears on your dashboard. It could be something simple, like time for an oil change, or it could be something bigger. What do you do? Lose your car for a day while you take it to a service station? Keep on driving and hope for the best?

  • DTNA’s (Daimler Trucks North America) engines continuously

record performance data and send it to their Detroit Diesel Customer Support Center (CSC). When a fault occurs, a team of CSC Technicians examine the data in real time and offer a

  • recommendation. If it’s just a routine repair, technicians can help

the driver schedule a service appointment for some convenient time and location.

  • But if it’s a more severe condition, they might say “You need to

bring your truck in for service right away. There’s a service station 75 miles down the road. When you get there, we’ll have a service bay open and all of the parts we need on hand. You should be in and out in two hours.”

  • eCommerce enables parts movement seamlessly across service

stations

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SLIDE 43

31 May 2016

Warehouse Safety and Automation RoundTable

31 May 2016

Warehouse Safety and Automation RoundTable

Shailen Shukla

Discussion Issues

  • Warehouses in this region need

to be upgraded in terms of safety, security, health—comments, pros and cons?

  • There are safety and health

centric standards applicable in many advanced countries. Has the region adopted such standards inside warehouses to full extent? Is there a need and scope of region specific safety, health standards to be devised, communicated and regulated?

  • What’s the most pressing supply

chain issue in region and recommendation to resolve— policy or strategy centric?

  • Region has challenges in terms of

not meeting requirements of food or pharma cold chain supply chain standards. There could be a need of bringing processes, policies and regulatory mechanisms.

  • How do you see adoption trend
  • f automation in supply chain

space? Robots are coming in at multiple work places. Warehouses will see more and more robots across globe.

  • Automation in warehouses will

need investment. Is there well authenticated rate of return promised from automation?

slide-44
SLIDE 44

31 May 2016

Warehouse Safety and Automation RoundTable

31 May 2016

Warehouse Safety and Automation RoundTable

Shailen Shukla

Thank You