Management Gemba

Title Page

Gemba Performer
Region
Facility Type
Facility Name
- FM Johar Town Station
- FM Hall Road Station
- FM IqbalTown Station
- FM Harbanspura Station
- FM Model Town Station
- FM Shah Alam Station
- FM DHA Lahore Station
- FM Saddar Lahore Station
- FM Baghbanpura Station
- FM Township Station
- FM PWD Station
- FM Liaquat Road Station
- FM Blue Area Station
- FM Commercial market Station
- FM Adayala Road Station
- FM North Karachi Station
- FM II Chundrigarh Station
- FM Saddar Station
- FM Shaheed e Millat KHI
- FM AyeshaManzil Station
- FM Gulshan Station
- FM Nazimabad Station
- FM Defence Zamzama Station
- FM Sharah Faisal Station
- FM Defence Phase 2 Station
- FM Garden Station
Facility Name
Facility Name
Facility Name
- LM KLP
- LM DHA-3
- LM SMN
- LM LAX
- LM ISL
- LM RWS
- LM RWP
- LM IST
- LM BDD
- LM CTN
- LM NAZ
- LM KOR
- LM SAD
- LM Malir
- LM Scheme 33
- LM GUL
Hub Name
- Abottabad Hub
- Bahawalpur Hub
- Faisalabad Hub
- Gujranwala Hub
- Gujrat Hub
- Hyderabad Hub
- Jhelum Hub
- Multan Hub
- Okara Hub
- Peshawar Hub
- Quetta Hub
- Sahiwal Hub
- Sargodha Hub
- Sheikhapura Hub
- Sheikhapura Hub
- Sialkot Hub
- Sukkur Hub
Conducted on
Geo Location

Management Gemba Guidelines

Please select OK if no observation and NG if any observation.
Please ensure to follow the given time allocation for each section:
Please adhere to the following guidelines while performing the Gemba:
- Observe and gather information.
- Do not change anything on the spot.
- Do not criticize the employees working.
- Keep record of every observation and attach picture incase of NG.
- Get insights from employees
- Understand the challenges faced by the workers

5S & Package Handling

5S Guidelines

While checking for 5S observation please keep in mind the following points.
- Labelling condition of shelves, station and bins.
- Floor demarcation condition.
- Equipment and items placed as per labelling and demarcation.
- 5S champion selected and displayed.
- Dirt, oil or grease on floor, walls or stairs.
- Garbage in working area.
- Gemba checklist being utilized.
- Cleaning checklist being utilized.
Is there any 5S related observation in the Facility?
Please describe the 5S observation.
Proposed Action/Counter-Measure for the 5S observation.

Package Handling

While checking for Package Handling observation please keep in mind the following points.
- Boxes/carton/package is not kept on floor.
- Boxes are stacked in such a way that they don’t fall off due to imbalance with proper weight
distribution.
- Fragile packages/ LED must be place in separate portion/ Asper policy & stack in Arron direction.
- Sacks are not dragged on the floor.
- No throwing of any sort of package into trolley/carton from distance.
Is there Package Handling related observation?
Please describe the Package Handling observation.
Proposed Action/Counter-Measure for the Package Handling observation.

Admin & Safety

Admin

While checking for Admin observation please keep in mind the following points.
- Kitchen staff is following all hygiene protocols and kitchen area is clean. No pest intrusion is
observed inside kitchen.
- Building walls and ceilings condition.
- Customer Area condition.
- Operation Area condition.
- Outside Area condition.
- All assets maintain their structural integrity and are free from visible signs of bending, warping, or
deformation.
- Are there any faulty electrical fixtures? Is building wiring in good condition?
- Are washrooms are cleaned and in good condition?
- Is the facility pigeon/bird free?
Is there any Admin related observation in the Facility?
Please describe the Admin observation.
Proposed Action/Counter-Measure for the Admin observation.

Safety

While checking for Safety observation please keep in mind the following points.
- Is there proper ventilation in the workspace?
- Are the safety equipment and supplies in clear and obstacle free?
- Are there no safety hazards (water/oil/chemicals/open electrical wiring) in the working area?
Is there any Safety related observation in the Facility?
Please describe the Safety observation.
Proposed Action/Counter-Measure for the Safety observation.

General Operations (SOP)

Facility Type
While checking for FM General Operations observation please keep in mind the following points.
- Is self inbounding system operational in designated Model Hubs.(Ensure availability of Scanners,
LEDs & Smooth internet Connectivity, availability of trollies/pallets to keep processed and
unprocessed packages)
- Primary sorting is carried out based on Regular and Irregular Packages or Fragile and Non
Fragile?
- Station Staff will conduct a Smart QC before receiving the item.(Check for physical condition &
Customer Claim in LOP)
- Bar Code are installed on every location where CP package is kept
- For FD Packages, If the seller collects the package within 7 days, a system generated receiving is
given, otherwise the package is marked as Scrap(PSC team will be communicating with the seller).
- RTM/RTC/RTW/SCRAP packages are placed in the standard color bins.
While checking for Sort General Operations observation please keep in mind the following points.
- Are the docks clear for parking the Inbound vehicle?
- Are the pallets placed at Inbound for unloading the MUs from inbound vehicle?
- Are the pallets placed at Inbound conveyor for placing the MUs (that are to be loaded on Inbound conveyor)?
- Are the pallets placed at the end of Outbound conveyor? (for unloading the out bounded MUs of the machine).
- Parcels greater than BOX003 are being placed at semi-bulky area.
- Irregular shaped parcels (coming inside MUs) are being stopped at Induct stations (Refer to SOP)
- DEX packages are sorted according to 1) based on same city or different city and 2) Based on last mile hub
- 3PL packages are sorted based on 3PL name irrespective of the destination.
- Inbounding is done on package level . In case of high backlog and/or missing packages, Sort Team will initiate the FM Team within 24 hours and Route/Station will be responsible for the loss.
- Are large packages with a Non Bulky Tracking number re-shipped to bulky?(check for Gdoc)
- Is the Inbounding of CB packages done after intimation from CB team(transport team)?
While checking for FF General Operations please keep in mind the following points.

FF Inbound
- Consignment shall be received only if the vendor has the Purchase order
- Receiver physically checks inbound order and reconcile with item/box level receiving
- Purchase order needs to be stamped after stock receiving

FF Inventory
- Physical stacking location and system stacking location should be the same
- Are the inventory capacity levels maintained? (as defined in the policy)
- B Zone: SKU Limit (5)
- F Zone: SKU Limit (3)
- S Zone: SKU Limit (3), Bin Color (Green, Blue & Red)
- H Zone: SKU Limit (3), Bin Color (Green & Blue)
- P Zone: SKU Limit (3)
- L Zone: SKU Limit (4)
- Troubleshoot Bin must have correct and relatable items
- High Value Entry/Exit log is being maintained

FF Outbound
- Wave is being run by the authorized person
- Single Bin is being used for single Picklist
- Item are getting packed in correct boxes

FF QCC
- QC agent are putting the RTC/ RTM/ RTW Scrap in their respective bin after making logistics closure
- Receiving trollies are marketed with dates, to comply with FIFO
- For Electronics, if complaints are regarding quality issue, QC Agent will perform QC for greater than Rs.1000, else RTC for less than Rs.1000
While checking for LM General Operations observation please keep in mind the following points.
- Is Inbounding done at MU Level for Non-Bulky Packages?
- Is Inbounding done at Package Level for Bulky Packages?
- Are the packages that are being reshipped contain dual addresses (L3,L4 Vs Text box)?
- MU are placed based on L3.8 level sorting? i.e. Chute
- At the time of exit, physical packages are checked against the RS to check for any extra or shortage of packages.
- IVR hold, reject and reschedule bins are correctly labelled.
- Reject tape is pasted on the Reject packages before sending it to relevant SC.
- Packages are sorted as per drop-off location and MUs are created with respect to the drop-off location.
Is there General Operations related observation?
Please describe the General Operations observation.
Proposed Action/Counter-Measure for the General Operations observation.

Employee Engagement & Observation and Recommendations

Employee Engagement

While engaging with the employees, please keep in mind the following point.
- Ask employees if there is any improvement that an be done to in the system?
- Ask if there any challenges that the employees face?
- Are the employees satisfied with the current management style of the facility?
- Ask the employees if they are regularly trained for the job?
- Any additional concerns or issues brought up by employees on the floor?
- Ask employees if there efforts are recognized and appreciated?
- Ask the 5S champion what can be done to improve the implementation of 5S practices and spread awareness among the employees.
Is there any employee related observation in the Facility?
Please describe the employee related observation.
Proposed Action/Counter-Measure for the employee related observation.

Additional Observation and Recommendations

Specify the observation category.
- Processes and Asset’s efficiency/ optimization
- Facility Maintenance / Asset
- Security and Surveillance
- Other
Please describe the observation.
Proposed Action/Counter-Measure for the observation.