According to the current situation of Zhuhai Gree and their requirements, fablog had carried out the improvement work in the following aspects: the improvement of warehouse capacity, the adjustment of warehouse layout, the optimization of inventory structure, the warehousing organization of inbound materials from suppliers, the improvement of warehousing efficiency, the optimization of warehouse location management, the optimization of outbound materials, the optimization of line feeding mode , and the impovement of IT system functions, equipment personnel allocation calculation, investment analysis and corresponding operation process planning.

Project background:

Founded in 1991, Zhuhai Gree Electric Co., Ltd. is the world's largest professional air-conditioning enterprise integrating R & D, production, sales and service.

At present, Gree Zhuhai plant has 8 phases, 59 production lines and 4 raw material warehouses. Due to the long time span of the whole plant, the production and logistics planning of each phase of the branch plant is totally different, and almost all the supporting material warehouses are buildings, with limited space and low effective utilization rate. In recent years, with the rapid expansion of production capacity and the promotion of the small batch and high frequency production mode required by the order, the warehouse capacity, the operation efficiency of the in and out warehouse, the accuracy of production logistics distribution, the support of IT system and other aspects gradually become the bottleneck restricting the further improvement of its production.

Project content：

Fablog was invited by Gree company to carry out improvement work from the following aspects according to the current situation and customer requirements, specifically: the improvement of warehouse capacity, the adjustment of warehouse layout, the optimization of inventory structure, the warehousing organization of inbound materials from suppliers, the improvement of warehousing efficiency, the optimization of warehouse location management, the optimization of material picking out of warehouse, and the line feeding mode , it system function improvement, equipment and personnel allocation calculation, investment income analysis and corresponding operation process planning.

In terms of warehouse optimization, we set up the incoming call system to organize the unloading operation of suppliers, improve the unloading efficiency and improve the disorder of unloading vehicles in the factory; clean up the dull materials, transfer the reserve materials to the external warehouse, improve the flow speed and effective space utilization of the existing warehouse; set up a dual core warehouse to effectively reduce the traffic pressure in the factory to improve the response speed of material demand; to carry out bar-code warehouse location management of warehouse location, and readjust the warehouse layout and location distribution of material types, to reduce the problems of indefinite storage status, location and long searching time of materials, so as to improve the efficiency of material storage operation and sorting operation.

By setting different line feeding mode, Fablog reduced the quantity of line side materials from 24-hour demand to 6-hour demand, and now is improving it towards 2-hour demand, so as to reduce the inventory of line side materials and improve the efficiency of line feed sorting operation; strengthen the complete set inspection of materials before line feeding, reduce the frequent changes in production plan; complete set distribution of materials in time zone, reduce the need for material delivery staff to check every time. Three kinds of materials lead to low efficiency of operation; KLT standard，pallet standard are implemented.

 In the aspect of IT system and process optimization, by optimizing the matching relationship between batch code and materials, adding the generation module of picking list, optimizing the corresponding operation process, enhancing the IT system's guidance and error proofing efficiency for operation, improving the efficiency of material storage, and the consistency of accounting; integrating the transportation and distribution business between the fleet and the warehouse, reducing the internal handover link, so as to make the logistics process Smoother. Measure and match the resource demand, allocate personnel positions and equipment distribution.

Through the above measures, Fablog impoved Gree plant material inbond and outbound  efficiency, warehouse capacity rate, flow operation smoothness, accuracy of material distribution and reduced the line side inventory.