MODULE 7 Warehouse Processes from Replenishment to Dispatch and Beyond

Question 1

T or F
Replenishment is the activity of transferring goods from reserve stock (or sometimes directly from goods-in) to the picking face.

Answer 1

True

Question 2

It is not important to design the replenishment task because it is not effective but also interfere with the picking task

Answer 2

False
It is important to design the replenishment task not only so that it is effective but also so that it does not interfere with the picking task,

Question 3

Replenishment is often triggered when the pick face only has a certain quantity of goods left.

Answer 3

True

Question 4

A similar layout is possible using ground-level pallet-live storage.

Answer 4

True

Question 5

Undertaking the replenishment and picking tasks at different times of day

Answer 5

True

Question 6

Having multiple locations for fast-moving goods
replenishers and pickers are not operating at the same pick slot.

Answer 6

True

Question 6

Having multiple locations for fast-moving goods
replenishers and pickers are not operating at the same pick slot.

Answer 6

True

Question 7

It should always be remembered that successful order picking is dependent on an effective
replenishment operation.

Answer 7

True

Question 8

Many warehouses have introduced areas where value-adding services can be carried out

Answer 8

True

Question 9

Postponement can be described as a delay in the completion of an item until an actual order is received from a customer

Answer 9

True

Question 10

Postponement not only saves time but reduces inventory holding by reducing the total number of SKUs held in stock.

Answer 10

True

Question 11

Value-adding services don’t include returns processing and a repair service

Answer 11

False
Value-adding services can also include returns processing and a repair service

Question 12

Indirect activities are activities that occur in warehouses and are crucial to the efficient operation of the warehouse

Answer 12

True

Question 13

Warehouse managers are in a position to advise their inventory colleagues on levels of safety stock and the specific movements and characteristics of particular stock items.

Answer 13

True

Question 14

Majority of warehouse managers are not involved directly in the choice, purchase and replenishment of stock,

Answer 14

True

Question 15

A warehouse manager can extend the normal classification to include non moving and obsolete stock together with identifying stock

Answer 15

True

Question 16

Stock Classification “A” is for Medium Moving Items

Answer 16

False
Fast Moving Item’s

Question 17

Stock Classification “B” is for Medium Moving Items

Answer 17

True

Question 18

Stock Classification “C1” is for Slow Moving Items

Answer 18

True

Question 19

Stock Classification “C2” is for Very Slow Moving but required for Cover

Answer 19

True

Question 20

The percentages will not vary significantly by company and by market sector

Answer 20

False
The percentages will vary significantly by company and by market sector

Question 21

Maintenance stores are likely to have a high proportion of their stock in the A to X categories

Answer 21

False
Maintenance stores are likely to have a high proportion of their stock in the C to X categories

Question 22

All warehouses are not obligated to undertake some form of stock count

Answer 22

False
All warehouses are obligated to undertake some form of stock count

Question 23

It doesn’t depends on the law of the country and accounting requirements as to how frequent and comprehensive the count is.

Answer 23

False
It depends on the law of the country and accounting requirements as to how frequent and comprehensive the count is.

Question 24

A full stock count is not usually necessitates the closure of the warehouse for a period of time when all inbound and outbound movements are suspended.

Answer 24

False A full stock count usually necessitates the closure of the warehouse for a period of time when all inbound and outbound movements are suspended.

Question 25

A significant drawback of a single annual count is the difficulty in reconciling the discrepancy

Answer 25

True

Question 26

The count is normally carried out at the company’s year-end

Answer 26

True

Question 27

auditors don't agreed in some cases that if each stock line is counted and audited at least once per annum that will be sufficient for their needs.

Answer 27

False auditors have agreed in some cases that if each stock line is counted and audited at least once per annum that will be sufficient for their needs.

Question 28

Providing the cycle counts are considered to be accurate, the year-end stock figures will be taken from the WMS.

Answer 28

True

Question 29

Security of product within the warehouse is not paramount

Answer 29

False Security of product within the warehouse is paramount

Question 30

The warehouse manager is somewhat not responsible for the integrity of all the products under his or her care, whether they are owned or stored on behalf of other companies as a third party contractor.

Answer 30

False The warehouse manager is responsible for the integrity of all the products under his or her care, whether they are owned or stored on behalf of other companies as a third party contractor.

Question 31

Security can't be achieved through good housekeeping only

Answer 31

False Security can be achieved through good housekeeping

Question 32

Poor security costs companies in lost inventory, higher insurance premiums and personnel turnover.

Answer 32

True

Question 33

Security systems tend to be designed to protect your facility from people breaking in – but many thefts are perpetrated from within.

Answer 33

True

Question 34

Not only is product security important but also the protection of data.

Answer 34

True

Question 35

Protecting data from being stolen or copied is also paramount

Answer 35

True

Question 36

Returns processing, or reverse logistics as it has become known, involves the handling of product returns, transit packaging and surplus items

Answer 36

True

Question 37

The processing of returns has gained increasing importance in the warehouse over the past few years.

Answer 37

True

Question 38

The Waste Electrical and Electronic Equipment Directive came into force in January 2007 in the EU. Its aim is to both reduce the amount of electrical and electronic equipment being produced and to encourage everyone to reuse, recycle and recover.

Answer 38

True

Question 39

The increase in e-retailing has also seen a significant increase in the level of returns into the warehouse.

Answer 39

True

Question 40

Product recalls are also a significant area, needing to be handled carefully.

Answer 40

True

Question 41

Return Processing Warehouse is a type of warehouse needs to be set up very differently from a stockholding facility.

Answer 41

True

Question 42

The idea behind returns processing is to either return stock into the supply chain as quickly as possible in whatever format

Answer 42

True

Question 43

Returned items shouldn’t remain in the facility for too long this needs to be carefully planned to avoid cross contamination

Answer 43

True

Question 44

Reverse logistics has gained momentum recently and has gone from being driven by environmental concern to becoming a corporate cost-reduction programme.

Answer 44

True

Question 45

According to Stock/WERC (2004) ‘the keys to any successful product returns program are having the right combination of people, policies, procedures and priorities’.

Answer 45

True

Question 46

The order cycle time or lead time from order receipt to despatch is continually shortening and there is increased pressure on the warehouse manager to coordinate all activities to ensure that product is despatched on time and complete.

Answer 46

True

Question 47

Packing – pieces/items/eaches ,This reduces the number of touch points in the warehouse but does take the operator away from the prime task of picking.

Answer 47

True

Question 48

Full carton despatch is somewhat easier to manage

Answer 48

True

Question 49

Velcro has introduced pallet straps to secure cargo

Answer 49

True

Question 50

The use of returnable packaging is also growing under environmental pressure

Answer 50

True

Question 51

The efficient loading of containers and trailers is crucial in today’s environment of rising fuel prices.

Answer 51

True

Question 52

Efficient loading of vehicles and containers begins with the initial packaging of the products.

Answer 52

True

Question 53

Pallet loads need to be configured to ensure that product damage is minimized

Answer 53

True

Question 54

This sophisticated software optimization not only takes into account the cube of the products but also their load bearing strength and location within the container.

Answer 54

True

Question 55

Many operations are now taking orders late into the evening and despatching that same night for next-day delivery.

Answer 55

True

Question 56

Collecting vehicles should be assigned a bay closest to where the orders have been accumulated

Answer 56

True

Question 57

Many companies have grids marked out on the warehouse floor at the despatch area to replicate the floor area of the largest vehicle.

Answer 57

True

Question 58

Companies with sufficient yard space and available trailers can load product directly into them and park them up, awaiting collection.

Answer 58

True

Question 59

The trailer should also be checked to ensure that it is fit for purpose

Answer 59

True

Question 60

A tyre manufacturer recognized a number of advantages after introducing three telescopic booms into the operation. These conveyors can also be moved sideways to cover a number of dock doors.

Answer 60

True

Question 61

ROI and payback can be significant in terms of labour saving, increased accuracy and less damage.

Answer 61

True

Question 62

Finally, despatch documentation and labelling needs to be completed to ensure compliance with customer requirements and government legislation

Answer 62

True

Question 63

Different countries will have same requirements and these will also differ if shipments are within country or for export.

Answer 63

False Different countries will have different requirements and these will also differ if shipments are within country or for export.

Question 64

Any errors in the export paperwork can result in non-shipment, seizure, fines or delays.

Answer 64

True

Question 65

When shipping hazardous material it is essential that products are labelled accurately and have the correct documentation.

Answer 65

True