Multinational FMCG Manufacturer
Investigate warehouse damages and stock losses of around 20% in finished goods warehouse. Gap turned out to be due to semi-literate forklift drivers not being able to read pallet labels and pallet stacking instructions. This lead to product being damaged by forklift drivers stacking two 700kg pallets (1400kg) on top of a 200kg pallet. UK head office ERP system generated pallet labels was modified to include stacking images (Top [light pallets], Middle, Bottom [heavy pallets]) that allowed semi-literate forklift drivers to see where they should stack a pallet. Stock damages and losses reduced from 20% to 4.3% within 4 days.
Improvement of pallet labels, training of all forklift drivers resulting on saving more than US$6 million per annum
$ 6 079 027.36