Nur Syakila Binti Muhiddin
2015839982
BM244 6N
A case study of Cartons Damaged at Top Glove warehouse
INTRODUCTION
1.1 Background of company
1.2 Background of study
1.3 Problem Statement
1.4 Research questions and objectives
Logo of company
TOP GLOVE SDN BHD
- The world’s largest rubber glove manufacturing.
- Operating 28 factories, 512 production lines and with a capacity of approximately 48.0 billion gloves per annum.
- An export about 195 countries worldwide and almost 2000 customers.
- The business direction is to produce consistently high quality gloves at efficient low cost.
- Mission Strive to the world’s leading manufacturer with excellent quality glove products and services that enrich and protect human lives.
- Vission To be a world class glove manufacturer providing top quality products with excellent services through continuous improvement and innovation.
TOP GLOVE SDN BHD
- Focused about cartons damaged at Top Glove warehouse which is including factors and effect of cartons damaged.
- Carton is an important packing material to protect goods and it is the interface towards the customers.
- In manufacturing all of aspects become important include low cost manufacturing, quicker product development, fast delivery, wider variety products, wider range of efficient production volumes and steadily increasing quality standards.
- Company in competitive world now should improve quality of their products and services for their customers while keeping a cautious eye on the cost factor.
A case study of cartons damaged at Top Glove warehouse
A case study of cartons damaged at Top Glove warehouse
- According data collected starting from January until April 2017, have some factors of cartons damaged that has happened and the effects are directly towards company because of cost and process of shipment.
- For example, on February 2017 cartons damaged are 4 cartons. Then the next month is 9 cartons and become 22 cartons on April.
- The effects is towards cost and process of shipment which become delay process.
- This problem is also related to customer trusts. They will expect company can deliver and arrived the container at port with exact time without delay or shut out.
- Cost of damaged also need emphasized so that company still achieve demand from customers and sales also increasing.
Research objectives and questions
Research objectives and questions
Research Objectives
- What are the factors that influence of cartons damage?
- What the effects of cartons damaged at Top glove warehouse?
Research Questions
- What are the factors that influence of cartons damage?
- What the effects of cartons damaged at Top glove warehouse?
OUR PROPOSAL
Label 1
2017
70 %
Label 2
2015
50 %
Label 3
2012
60 %
Data Collection
1. Interview
This survey is a two-way conversation between researcher and respondents.
2. Observation
Participant observations also means appropriate for gathering data on interactions and relationships through the recording of behaviour, conversation and experience.
3. SAP system
This system provides end to end solutions for financials, manufacturing, logistics, shipping and so on. It is also can make sharing information in the company.
Data Analysis
1. Pie chart
2. Bar graph
3. Histogram
4. Fishbone diagram
FINDINGS
- Respondents
- Total order of cartons damaged
- Cartons damaged from packing & warehouse dept.
- Fishbone diagram of cartons damaged
Respondents
- Most of the respondents are from warehouse staffs and workers which is 63%. It is because researcher easy directs to them and do observation during loading process.
- Some of managerial persons and workers had been interview such as executive warehouse, supervisor warehouse, assistant supervisor, loading workers and forklift driver at warehouse about cartons damaged.
- Respondents from packing department are 31%.
- Lastly for respondents is from purchasing department which is 6%.
Total order of cartons damaged
Total order of cartons damaged
- The highest cartons damaged from packing and warehouse department is on April which is 22 damaged from both packing and warehouse department with 146 total orders from customers.
- The lowest cartons damaged from both departments are on February which is 4 cartons damaged with 160 orders.
Cartons damaged from packing & warehouse dept.
Cartons damaged from packing & warehouse dept.
- Total cartons damaged from packing and warehouse department is 155 cartons damaged which is packing 153 cartons from packing department and 2 cartons from warehouse department.
- The highest of cartons damaged is from packing department.
- Cartons damaged happened after packing department packing all gloves into inners and cartons before transfer to warehouse to next loading process.
- Damaged can be happened from packing side is when workers wrapping cartons.
- Damaged is because of packing tape.
- At warehouse, it is because accident from forklift driver them self and not driving with carefully. According forklift driver, sometimes cartons damaged because condition of uneven road. It is because when cartons have been taken with forklift at uneven road, it is possible of cartons rocking and falling.
Materials
- Packing materials is to protect and packing gloves before sent to customers.
- Dimension of PM is divided by two which are in-house and request from customers.
- Specification that Top Glove Company towards suppliers selection is price, materials and the most important is quality.
- Usually if packing materials got problems such as dented, damaged because of new dimensions from customers.
- Suppliers printed those cartons.
- Opinion from purchaser which is executive PM is agree with statement from executive warehouse which states packing materials is a factor of cartons damaged happens.
- roles of pallets also should be emphasized. Arrangements of cartons must put at plastic pallets only.
Method
- Loading planning method is a proper plan. It means better if loading workers and supervisor plan earlier loading plan and pattern - they can know how much cartons can be loaded in one container.
- Cartons have different dimensions according brands and sizes - need to plan loading process according sizes by sizes so that can avoid from violation with other cartons.
- Handling materials equipment such as forklift and jet at warehouse is use for any movement of cartons at manufacturing.
- This factor carton can be damaged which are uneven road and when forklift driver want to pick pallets especially plastic pallets.
- Planning and monitoring is more focus about arrangement and transfer all cartons to warehouse.
- The staff will monitor all arrangement of cartons at warehouse - cartons in good condition and protect from sunlight and rain - cartons have been arranged in the warehouse and also cover with canvas at outside of warehouse.
Manpower
- Lack of manpower actually was raised at meeting with top management by Head of Department
- When workers are not enough during loading, it will take a long time to complete the loading - workers fast loading - they will be missed out or not noticed cartons damaged - did mistake until cartons can be damaged .
- Lack of manpower - affects toward efficiency in working process.
- One worker needs to do multi job to cover all works can going well - working process will become slowly and inefficiency
- Staffs need to find additional workers from different department to help warehouse workers to continue working and become efficiency.
Management
- Head of Department warehouse (HOD) schedule what group need to load goods according types of containers.
- Management want to make both of groups is balance with loading process - can focus and concentrate about their loading - avoid from cartons damaged. Workers no need to rush loading if have many container that need they to complete.
- Provide more canvas to cover all cartons - many of cartons and stocks are keep at outside of warehouse - management should double protect to cover all cartons.
- need to tighten rules or procedures towards workers to avoid cartons damaged - demerit through give training letter or warning letter.
Effects of cartons damaged
- Delay of process shipment
- Additional cost
EFFECTS
Delay of process shipment
Delay of process shipment
- When noticed have cartons damaged - will return back ...
- When noticed have cartons damaged - will return back to packing department to do rework again. Because of late or delay rework, it will effect towards efficiency of loading, and take a long time haulier to truck out.
- Delay of rework - hired new workers, unskilled or inexperience to do work - need to train so that rework process can be efficient and make it fast.
- Effect when delay of rework - haulier need to wait to truck out on that time and become delay or not meet the exact time.
- Have possibility late delivery to port but haulier tries to arrive at port before actual closing - if not the container will be shut out.
- Shut out means container already truck out from warehouse but cannot enter vessel because of delivery late. Effect of that is customer will complaints towards company.
- Roll over means when container is not ready to complete because cartons or packing materials is not enough to pack for last minutes, quality of gloves and take long time to complete loading. So the last container cannot meet the actual closing and be roll over.
- Rework cost, storage cost and schedule delay for haulier to truck out from warehouse also give effect towards company.
- From January to April 2017; total of cartons damaged is 155 cartons.
- Cost of one carton is RM3.24 pcs. Cost for one inner is RM 0.28 pcs. Usually one carton can fill with 10 inners. So total of one carton is RM6.04.
- For storage and delivery cost, warehouse team not have to burden with storage cost.