DAILY UP FURNITURE
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Background
The client is a mid-sized furniture assembly factory in Mumbai, India, with fixed workbenches and zoned parts bins on the shop floor. In early 2014, the client placed a consolidated order for parts to support a new round of assembly work, requiring deliveries to be batched by workstation and assembly sequence to suit the limited on-site storage space.
Requirements and challenges
- Batch delivery matched to workstations: With no large staging area available, parts had to be delivered in 14 batches following the assembly line sequence, each batch corresponding to a different process and arriving neither early nor mixed with other batches.
- Consistent part specifications: Connectors, drawer slides, corner brackets and similar items had to be dimensionally consistent within each batch, avoiding secondary sorting on site that would disrupt assembly rhythm.
- Packaging and labelling requirements: Each carton had to be marked externally with batch number, workstation code and quantity, with no mixing of different specifications inside, so that workers could collect materials directly.
Specification and solution
- Parts list configured by workstation: Based on the assembly process sheet provided by the client, we split the parts into separate lists following the workbench order, with each batch containing only the categories required for its corresponding workstation.
- Uniform packaging specification: Small to medium corrugated cartons were used, with individual carton weight kept below 18 kg to allow manual handling and parts bin replenishment within the workshop.
- Pre-shipment labelling and inspection: Each carton carried a batch label and a packing list. Before dispatch, every carton was checked for quantity and specification to prevent mixed or short-packed items.
Delivery and outcome
- Completed in 14 batches: All parts were dispatched in 14 batches as planned, with arrival times aligned to the client's assembly schedule and no batch sequencing errors.
- Zero picking errors: After counting, the client confirmed 326 cartons across the 14 batches, with no records of mixed specifications or short quantities.
- Bin replenishment time reduced by roughly 30%: Because packaging corresponded directly to workstations, the time from goods receipt to parts bin replenishment was reduced by approximately 30% compared with previous orders.
Client feedback: the parts arrived on time, the carton labelling was clear, workers did not need to search through boxes for materials, and the assembly schedule was steadier than expected.
