About Customer
Customer, is an Indian multinational company that manufactures and markets agrochemicals, industrial chemicals, chemical intermediates, and specialty chemicals, and also offers crop protection solutions. customer products are sold in 150+ countries.
Industry
Agro-Chemicals / customer is the fifth largest generic agrochemicals company in the world
Business Objectives / Goals
1. Product Serialization
a. Primary, Secondary and Tertiary Packaging with Unique UID
b. Aggregation of product / packaging
c. Comply with GS1 Standards
2. To Identify the Counterfeiting, Product Infiltration/Diversion
3. "Country Specific - Legislation for Agrochemical Products (Subjective as per country legislation, Confirm if this is required in country)"
4. End to End - Unit Level Product Traceability
5. Farmer Loyalty & Schemes
6. "Farmer Engagement - Cross sell, - Localization, - Product Education etc."
7. Distributors / Retailers Loyalty
8. "Physical Inventory Tracking
- Inventory Visibility
- Inventory Assurance
- Spurious Inventory"
9. Tracking of Inventory Liquidation at Distributors / Retailers
10. Integration with SAP Warehouse Management
- Batch and Quantity Accuracy
- Product Freshness
- Product Returns
- Dispatch Validations
- Stock count/stock audit
- Intra location movement
- Mapping of finished goods to raw materials
Solution Description / Approach
Authorities, world over, are starting to impose stringent product tracking regulations, especially with respect to the Agriculture/Pesticide Industry to combat counterfeit, illegally imported or stolen products. These regulations require manufacturers to comply with certain requirements for bar-coding/QR-coding and serialization on product packaging. The challenge faced by Manufacturers is to incorporate the specified bar-coding and serialization processes in their current packaging units, without compromising the speed of the entire packaging process. Here, a customized Track and Trace System becomes an effective tool for manufacturers, affording them advantages like serializing of products at different packaging levels, obtaining reliable data and feedback. These application specific solutions are a winning combination of sophisticated vision systems and advanced software’s. A complete track and trace system provide the best possible control because it is capable of tracing the history of the product for giving maximum transparency to help tracking in the supply chain. This project will enable complete serialization & aggregation solution. Solution is also integrated with SAP, SAP CPI platform & SAP WMS. Order management, production processes and dispatch processes are integrated.
Implementation Approach
1. Submit detailed project plan – with Gantt Chart.
2. Workshop with Plant Project team
– Introduction of Project team and Communication matrix
– Discussion on Project Plan, Gantt Chart, Pre-Requisites (in Scope of UPL), System GA Drawing.
3. Mechanical Engineer Visit site to take required dimension of bottle line (only applicable if online Serialization and Aggregation is opted by the Plant Team)
4. Submission of System GA drawing for approval
5. System build & Testing
6. Weekly status update and Progress
7. Factory acceptance Test (FAT)
8. Onsite Installation & commission as per daily planned task - Gantt Chart.
9. Submit User manual + SOP & Training to respective responsible department
10. Run 1-2 Commercial Batch
11. Documentation: Handover & project closure.
Key Learnings / Challenges
Equipment supply chain issues
Lead time to change Artwork for accommodating QR codes on each SKU
Lack of Infrastructure at plant and depot to accommodate all equipment’s
Change management at factories and in field force processes/practices.
High level motivation required to scan the bar code at distributors & Retailers
Necessary expertise required for Integration of non-sap solutions with SAP and WMS
KPI’s
Tasks at Factory
Serialization / Printing
Dispatch
Inventory Tracking
KPI’s
Right Dispatch
Inventory Assurance
Time to Dispatch
Tasks at Warehouse
Receipt /Dispatch
Inventory Tracking
KPI’s
Right Receipt/Dispatch
Inventory Assurance
Time to Receipt/ Dispatch
Tasks at Distributor / Retailer
Inventory Liquidation
KPI’s
Secondary sales Tracking
Loyalty Scheme
Inventory Visibility
Tasks at Consumer end
Product Information
Invalid Code / product
KPI’s
Loyalty Schemes
Spurious Inventory
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