AS IS OPERATIONAL SUMMARY OF SPL

14.12.2019

RECEIVING
 Parts procurement schedule is received on monthly bases from Vendor procurement.
 Parts are procured from three different sources.

i) In-house ( procured from plant),

ii) Vendor parts.
iii) Imported parts.

 Vendor procurement initiates monthly parts procurement schedule through email.

 In reference to procurement schedule parts are received by SPL.
 Excel format file is created by receiving section to follow the demand.
 For every supply parts challan is checked and verified by receiving section in charge.
 Parts are received by checking physical quantity through weighing scale else through manual
counting.
 Parts are then stack in receiving area (0022 current SAP location).
 Parts Delivery Challan is then GR in SAP.
 After GR challans are moved to vendor procurement for further processing.
 If parts purchase order has less quantity as compared to parts received then an email is
routed to vendor procurement to initiate its purchase order quantity.
 After GR quality inspection work starts.
 Parts GR done are moved in quality bin.
 Parts are released from quality bin after its quality inspection has been completed.
 Parts not fulfilling quality inspection criteria are then rejected.
 In-house parts are received through tender in SAP.
 Relevant department (General Store) creates a tender in SAP for in-house parts.
 After parts are received physically, SPL receives its tender (0022 location).
 Parts received from in-house and through imported consignments are quality inspection
free, its quality inspection in not done in SPL.
 Parts received in Pack form that is in AHL packaging are directly GR in 0011 location (Packed
parts location).
PACKING
 Packing area is responsible for packaging of parts according to AHL standardized packaging.
 Packing area extracts parts back order report through SAP.
 After initializing back order, stock of unpacks parts (0022 location) is observed.
 Parts according to back order are then moved from receiving area to packing area as per
demand by packing area in-charge for packing process.
 Packing material of said parts is issued from packing material (0018) through issue
requisition.
 Parts are then converted from vendor packaging to AHL packaging.
 Parts are packed in two modes

i) Manual packing
ii) Machine packing

 Each part has its defined packing standard in which parts are packed and being followed by
packing area.
 After packing parts are transferred to stacking area.
 Parts are also moved in SAP from 0022 to 0011 (Packed parts location).
 Receiving acknowledgment is also taken from stacking area by packing area for its record
purpose on manual paper sheets.

STACKING
 Stacking area is responsible for inventory management of parts as well as stacking of finish
product (packed parts).
 Quantity and random checking of packed parts is verified by stacking area and then
acknowledgment of parts is given to packing area.
 After receiving parts from packing area parts are stacked in stacking area.
 Some of the parts are having fix storage location and other placed on different storage
location.
 Parts are stacked according to storage location.
 Issuing of parts to dispatch area for dispatches is also prime responsibility of stacking area.
 Urgent warranty parts and claim parts are also issue after receiving email from operation
team.
 Stacking department receives email regarding parts dispatch process from AHL operation
team.
 Stacking area teams unstack these parts according to parts process list.
 Parts are then handed over to dispatch area for dispatching of said parts process.
 Stacking team also dispatches parts to regional stores as well as SPL SKP through container
after verifying back order from SAP.
 Oil area is also comes under stacking.
 It deals with Oil, Filter Battery.
 Same operational process is followed in oil area.
DISPATCH AREA
 Dispatch is responsible for dispatching of parts to AHL parts dealers as well as to regional
stores.
 After receiving parts process email from operation team dispatch area works starts.
 Dispatch are receives parts from stacking area according to process list.
 Parts quantity is verified by dispatch team after receiving parts.
 Dispatch team extracts dispatch order no from process email received and then prints
dispatch order slips (picking slips) from SAP.
 After that different dispatch order slips of same dealer (sub accounts) are merged with each
order in order to make it a single consignment.
 After printing dispatch order slips, consignment is prepared.
 Consignment is prepared according to dealer.
 Every dealer has a different consignment.
 Every last carton of consignments has its delivery order summary sheet, summarizing type
of parts and its quantity.
 So that when dealer receive its consignment can verify its details by this sheet.
 When consignment is ready and its weight is taken, sticker (dispatch sticker) is being posted
on every single carton of consignment.
 Every sticker has following details on it

i) Dispatch date
ii) Dealer name
iii) Dealer address
iv) Consignment no
v) Line of dispatch

 After consignment is ready, consignment is handed over to logistics for dispatching.

 For every consignment copy of dispatch order slip is kept with dispatch area team for its
traceability and in case of any query it can be concern.
 Consignments after getting ready are handed over to logics team for its dispatches which is
a part of dispatch team
 Logistics team manages vehicle management for parts delivery to different dealers within
the city as well as outside the city.
PACKING MATERAIL
 Packing material team is responsible for providing packing material for parts packing and
inventory management of packing material.
 After receiving parts procurement schedule packing material team generates its packing
material procurement schedule.
 Packing material demand schedule is generated by keeping in view that type of packing to
be used for each particular part.
 After demand is generated, email is sent to local purchase department for its procurement.
 Local purchase sent supply schedule to its packaging material vendors, and also provides its
copy to packing material team for its receiving.
 After receiving schedule vendors prepare material and sent it according to demand to SPL.
 SPL team receives packing material according to demand schedule vendor wise provided by
local purchase department.
 For every supply of packing material its delivery challan is verified according to demand, its
color is verified as well as quantity.
 After fulfilling above mentioned criteria packing material is received.
 After receiving packing material its delivery challan GR is done is SAP.
 And challans are forwarded to local purchase for further processing.
 Packing area team creates packing material Issue requisition and forwards it to packing
material team for its issuance.
 Packing material team receives issue requisition from packing team and then issues packing
material according to issue requisition.
 Packing material team also issues packing material to OSP (outsource process) vendors for
packing.
 After issuance of material its issue requisition is created.
 After that packing material is charged off in system.