Business Continuity Plan for Warehouse Operations

Few days after we have deployed the new system, major issues raised from the Operations, impacting the overall service performance for the warehouse.
The bar-code scanning system is corrupted.  This results intermittent dispatch issues and has slowed down freight processing at normal speed.  Current backlog has increased by 1.5 days and delays are being experienced in the hub network.   Systematic fixes are in place to clear them by working a 2 -shift operation; 24hrs a day across all warehouses.
Operations have to manually assigning freight to get customer deliveries out the warehouses.  Priority is given to oldest orders, anything with Fixed Delivery Dates, expedited, VIP etc.  Only critical issues are escalated as this point.
For the above case, this is an important lesson to all of us to have a business continuity plan and technical roll-back plans in place.  It is also important that such plans must be implemented and tested with the required parties even before the actual system cutover takes place in Production.  Below are the issues that faced from the unprepared cutover.
Issues to consider for mitigation plans for warehouse operations
  1. Label printing issue – slowness in printing 1 label (should not be more than 20 secs to print a label)
  2. No auto-generation of packing slips, shipping labels etc.
  3. Wrong information on the labels
  4. Bar-code scanning issue – product code  ID is scanned on picking bulk, but shown as none for the actual product
  5. Interface issues with call center and transport management systems – information are not sent on-time or not connected to these 2 systems.
  6. Wrong information shown for required order types
  7. Wrong assignment in carrier logic
  8. Data migration issues – using right  spreadsheets to gather correct information and upload to the systems in the later stage
  9. Resources’ mobilization (if required) to contain the situation

This is a costly lesson we have to learn and improve ourselves going forward.


    1 Response to “Business Continuity Plan for Warehouse Operations”

    1. April 18, 2013 at 8:58 am

      What’s up colleagues, how is all, and what you wish for to say regarding this piece of writing, in my view its truly amazing for me.

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