Project Initiation : 2020
Associates Deployed: 200+
Engagement Type: End-to-End Stores & Logistics Management
The Challenge
In 2020, Our Client faced a critical need to streamline their internal supply chain functions across multiple store units—including Trim, FRP, Paneling, IDM, Paint, Steel, and Machine Shop. The challenge was not just operational execution, but ensuring material movement happened with precision, predictability, and zero disruption to production lines—while maintaining World Class Quality (WCQ) and adhering to 5S protocols.
The Layam Solution
Layam Group stepped in as a complete operational partner, deploying over 200 trained associates across 8 store divisions. Our integrated Stores & Logistics Management Model took ownership of every stage—from receiving and binning to kitting, line feeding, and real-time SAP integration.
Key Strategic Deliverables
- Total control over end-to-end supply chain (Receiving → Line Feeding)
- Kitting aligned with real-time PPC Plan
- On-time material delivery across shifts with advance BOM prep
- Inventory accuracy through Daily Physical Inventory checks
- Implementation of FIFO & WCQ standards
- Complete SAP data control & escalation protocol
- Rejection material tracking and feedback closure
The Process Engineered for Excellence
Receiving & Verification
- Part condition & quality verification
- GRN generation and SAP updates
- Real-time binning list preparation
Binning & Mapping
- Systematic bin audits & stock sync
- Bin mapping and register maintenance
- Daily PI for physical-system alignment
Kitting & SAP Integration
- BOM-based kit creation
- SAP location check & updates
- Indent-based trolley preparation for shift readiness
Line Feeding & Feedback Loop
- Signature-based validation at production line
- Empty trolley return cycle
- Rejection note system for damaged parts
Results & Impact
- Zero Line Disruption across all shifts
- 100% SAP Data Sync with traceability
- Advanced Kit Readiness enabled faster assembly
- Shrinkage Reduced by 30%
- Daily PI Improved Accuracy by 95%
- 5S Implementation Across All Stores
Why It Matters?
This engagement is a testament to how Layam doesnʼt just deploy manpower – we embed precision-driven operations, technical system management, and production-aligned logistics into the clientʼs core supply chain. For employers, Layam becomes a seamless extension of the enterprise – reducing overheads, ensuring compliance, and elevating operational predictability.
