warehouse operations training matrix lka-log-100

Linc Knowledge Academy

Linc Knowledge Academy /Tupperware IndonesiaLKA-LOG-100 Warehouse Operations1 Sep 2012____________________________________________________________________________________________________________

Training Matrix for Warehouse Operations

S/NoReferenceCompetency UnitPage

1LKA-LOG-101-xWarehouse Operations, Forklift / Reach Truck Operation2 - 3

2LKA-LOG-102-xWarehouse Operations, Receive Incoming Cargo (including Put-Away)4 - 9

3LKA-LOG-103-xWarehouse Operations, Pick & Stage Cargo10 11

4LKA-LOG-104-xWarehouse Operations, Pack Cargo12 - 15

5LKA-LOG-105-xWarehouse Operations, Prepare for Delivery16 - 17

Reference: LKA-LOG-101-xCompetency Unit: Forklift / Reach-truck Operation

Essential Skill

The correct and safe operation of forklift and/or reach-truck is an essential skill element for all warehouse staff assigned to handle these equipment.

It is mandatory for all warehouse staff assigned to operate forklift or reach-truck to complete this Competency Unit.

Competency Elements

CE1Forklift / Reach-truck Operation

SS01SS02

On completion of training, the individual must be able to successfully perform the following:

Competency Element / Performance Required

Underlying Skill Set(Underlying Knowledge)Assessment Criteria(Candidate should be able to: )Assessment MethodApplication

Casual WorkerWH OperatorWH CheckerWH SupervisorStock Controller

CE1 Forklift / Reach-truck OperationSS01Perform Basic Operator Checks Demonstrate how to perform before and after operations procedure with reach truck / forklift.

Practical AssessmentXXX

SS02Safety and Operation of Forklift / Reach-truck Pick, travel and lower pallets correctly without damaging the products (bags cargo, cartons and oversize products) on the pallet and complying to safety rules.

Store and retrieve pallet from low level, high level and double-deep rack storage safely and correctly.

Practical Assessment


XXX

Reference: LKA-LOG-102-xCompetency Unit: Receive Incoming Cargo (including Put-Away)

Receiving Process

1

Preparation for Arrival of Cargo

2

Unloading and Palletizing3

Complete Receiving Documentation and Release Driver

4

Tally & Inspection of Cargo5

Prepare for Put-Away6

Put-Away

Competency Elements

CE2Prepare for Receiving

CE3Inspect & Prepare the Container / Lorry for Receiving

CE4Unloading Palletized and Non-Palletized Cargo

CE5Sorting & Palletizing Cargo

CE6Disposition of Packing Materials

CE7Completion of Documentation before Releasing DriverCE8Check Incoming Cargo against Inbound Tally Sheet

CE9Identify, Handle & Report Non-Conforming Products

CE10Prepare Cargo for Put-Away to Storage

CE11Identify Put-away Locations

CE12Put-away cargo into Storage (in accordance to Linc QMS)

SS03SS04SS05

SS06

SS07SS08

SS09SS10SS11SS12

SS13SS14SS15SS16SS12

SS17SS18SS19SS20SS21SS22

SS23SS24

SS19 not applicable for Tupperware Operation





CE2 Prepare for Receiving

SS03Concept of UOM, SKU and Packing Configuration Convert from SKU to equivalent number of packages and pallets needed for each receiving based on the packing configuration.

Oral Assessment

XX

SS04Select Staging Location

Select the appropriate staging location for the receiving / picked cargo.Written Assessment

XX

SS05Receiving Documents

Print Inbound Tally Sheet and check the key information across the different receiving documents to ensure correctness.

Oral/Written Assessment

XX

CE3 Inspect & Prepare the Container / Lorry for Receiving

SS06Inspect and prepare the container / lorry for receiving.

Inspect the container/lorry to spot tampering where receiving cannot proceed.

Prepare the container / lorry for unloading according to Quality System and safety guidelines

Oral Assessment

Practical AssessmentXX

CE4 Unloading Palletized and Non-Palletized CargoSS07Packing Symbols and Correct Handling Recognize the packing symbols and the care needed when handling it.

Oral Assessment

XX

SS08Unloading techniques and workplace safety guidelines Unload a palletized product from the container/lorry without damaging the products and complying with all the workplace safety guidelines.

Unload non-palletized product including bags and cartons from the container without damaging the products and complying with all the workplace safety guidelines.



XX

CE5 Sorting & Palletizing CargoSS09Types of Product Identification Perform sorting of products using the various identifications on products including: Item Code and Batch/Lot number Item Code and expiry date


SS10Types of Pallets and their usage Identify the different types of pallets used in the warehouse and explain their usage

Oral AssessmentXX

SS11Palletizing Techniques Perform palletizing for each type of cargoes including bags and cartons.


SS12Types of Non-Conforming Products Identify and separate non-conforming products (damages and poor (quality) packaging).

Practical & Oral AssessmentXX

CE6 Packing Materials & their DisposalSS13Types of Packing Materials Identify the different types of packing materials commonly used in warehouse including cartons, bubble wrap, corrugated paper, kraft paper, vacuum pack, packing foam, corner protectors, tapes and adhesives.

Oral AssessmentXX

SS14Recycling & Disposal of Packing Materials Sort and store packing materials that can be recycled and dispose those that cannot be recycled.


CE7 Completion of Documentation before Releasing Driver (in accordance to Tupperware QMS)SS15Documenting non acceptable Container Conditions List conditions of container that is unacceptable.

Prepare Equipment Interchange Receipt (EIR)

Prepare acknowledgement to release the driver.Oral Assessment


Oral Assessment

XX

CE8 Check Incoming Cargo against Inbound Tally Sheet (in accordance to Tupperware QMS)SS16Perform Tally (using the Inbound Tally Sheet) Check, verify, record and confirm receipt using the inbound tally sheet.

Prepare the Goods Receipt Inspection Report.



SS12Types of Non-Conforming Products

Identify and separate non-conforming products (damages and poor (quality) packaging)

Identify the non-conforming products in terms of wrong quantity and wrong product shipped.


Oral Assessment

XX

CE9 Identify, handle & Report Non-Conforming ProductsSS17Discrepancy Reporting Explain the discrepancy reporting procedure

Prepare discrepancy report (Goods Receipt Inspection Report, Berita Acara report and Accident Warehouse Report)Oral Assessment


SS18Quarantine Products and Storage Prepare and label quarantine products for put-away to quarantine locations.


CE10 Prepare Cargo for Put-Away to StorageSS19Pallet Identification Label(not applicable for Tupperware Operation Generate the receiving labels from WMS and paste them onto the correct pallets.


SS20Purpose & Techniques to Secure Cargo Perform the final checks and secure the cargo for storage using stretch wrapping.


CE11 Identify Put-away Locations

SS21Warehouse Storage Zone & Guidelines Apply the warehouse zone and storage guideline to put-away (pick) the required products.

Oral AssessmentXX

SS22Storage Location Naming & Assignment Identify the physical storage location for any given location name.


CE12 Put-away cargo into Storage (in accordance to Tupperware QMS)

SS23Put-Away Process using RF Perform RF-directed and non-RF-directed put-away of pallets to correct storage location.

Perform put-away of non-conforming products to the correct quarantine locations.



XX

SS24Proper Positioning of Pallet on the Rack Identify pallets that are not place correctly on the racks and which may pose safety hazards.Oral AssessmentXX

Reference: LKA-LOG-103-1Competency Unit: Pick & Stage Cargo

Picking Process

1 Receive Pick list

2Travel to Pick Location

3Pick Cargo from Location

4Travel to Staging Area and Unload

Competency Elements

CE13Interpret pick list and customers instructions

CE14 Prepare for picking

CE15 Identify the pick locations of the required goods.

CE16 Perform Picking

CE17 Handle discrepancies in picking

SS25SS03

SS04SS26SS21SS22SS27SS07SS09SS28SS12

SS29





CE13 Interpret pick list and customers instructionsSS25 Information in pick list and types of customers instructions

SS03Concept of UOM, SKU and Packing Configuration Identify the relevant field in the pick list and customers instructions used for picking.

Convert from SKU to equivalent number of packages and pallets needed for each receiving based on the packing configuration.

Oral Assessment

Practical PerformanceXXX

CE14 Prepare for pickingSS04Select Staging Area

SS26 Picking Priorities

Select the appropriate staging location for the receiving / picked cargo.

Plan the picking and prioritize them according to a set of guidelines.

Written Assessment


CE15 Identify the pick locations of the required goods.SS21Understand Warehouse Storage Zone & Guidelines

SS22Storage Location Naming & Assignment

SS27 Picking route / sequence

Apply the warehouse zone and storage guideline to put-away (pick) the required products.

Identify the physical storage location for any given location name.

Apply the guidelines to plan the picking sequence / route to minimize travelling time.

Oral Assessment



CE16 Perform PickingSS07Packing Symbols and Correct Handling

SS09Types of Product Identification

SS28 Pick using RF

SS12Types of Non-Conforming Products

Recognise the packing symbols and the care needed when handling it.

Perform sorting of products using the various identifications on products including: Item Code and Batch/Lot number Item Code and expiry date

Perform picking using the RF following good picking discipline and complying with workplace safety guidelines.

Identify and separate non-conforming products (damages and poor (quality) packaging).

Oral Assessment




CE17 Handle discrepancies in pickingSS29 Types of Discrepancies and Remedial Actions.

Apply the correct remedial action for a given discrepancy found during picking.

Prepare discrepancy report for follow-upOral Assessment


Reference: LKA-LOG-104-1Competency Unit: Pack Cargo

Packing Process

1 Sort and Check Cargo

2Pack cargo for export

Competency Elements

CE18 Sort and Check cargo

CE19 Handle Discrepancies found during packing

CE20 Pack products according to customers instructions

CE21 Measure and weigh packed products

CE22 Mark and label cargo in accordance with customers instructions

SS25SS07SS09

SS12SS30SS13SS10SS31SS11

SS32

SS33

SS32 Not applicable for TupperwareOn completion of training, the individual must be able to successfully perform the following:




CE18 Sort and Check Cargo (according to order)SS25 Information in pick list and types of customers instructions

SS07Packing Symbols and Correct Handling

SS09Types of Product Identification

Identify the relevant field in the pick list used for sorting and checking.


Perform sorting of products using the various identifications on products including: Item Code and Batch/Lot number Item Code and expiry date

Oral Assessment


Practical AssessmentX

CE19 Handle Discrepancies found during PackingSS12Types of Non-Conforming Products

SS30 Corrective actions to complete the order

Identify and separate non-conforming products (damages and poor (quality) packaging).

Apply the appropriate corrective actions to complete the order when discrepancies are found during packing.

Prepare Berita Acara Accident Warehouse Report and the Discrepancy report for follow-up.Practical Assessment

Oral Assessment



Underlying Skill Set(Underlying Knowledge)Assessment Criteria(Candidate should be able to :)Assessment MethodApplication


CE20 Pack products according to customers instructions SS13Types of Packing Materials

SS10Types of Pallets and their usage

SS31 Packing guidelines and safety

SS11 Palletizing Techniques

Identify the different types of packing materials commonly used in warehouse including cartons, bubble wrap, corrugated paper, kraft paper, vacuum pack, packing foam, corner protectors, tapes and adhesives.

Identify the different types of pallets used in the warehouse and explain their usage.

Perform packing of products for shipment/delivery without damaging them and complying with workplace safety.

Perform palletizing for each type of cargoes including bags,and cartons.

Oral Assessment

Oral Assessment



XX

CE21 Measure and weigh packed products (for shipment only)SS32 Purpose and Method of Measurement

(Not applicable for Tupperware) Weigh, measure and compute the volume, gross weight and net weight for a given packed cargo.


CE22 Mark and label cargo in accordance with customers instructionsSS33 Shipment markings and labels Mark and label a given packed order with appropriate identifications for shipment.


Reference: LKA-LOG-105-1Competency Unit: Prepare for Delivery

Receiving Process

2Handover of Goods to Driver

3Loading unto Truck / Container

4Release the Truck/Container

Competency Elements

CE23 Handover products to driver using Pick list

CE24Prepare loading plan (for container)

CE25 Load products unto lorry / container

CE26 Secure products for transport

CE27 Complete documentation to release driver

SS34

SS35

SS07SS36

SS37SS38





CE23 Handover Products to DriverSS34 Method and Guidelines for handover. Organise the handing over of products in one or many orders to a driver.Practical Assessment

XX

CE24 Prepare Loading PlanSS35 Purpose and Guidelines for loading plan

Prepare a loading plan for a container or lorry with palletized products and/or non-palletized products.Practical Assessment

XX

CE25 Load Products unto Lorry / ContainerSS07Packing Symbols and Correct Handling

SS36 Loading techniques and Safety Guidelines


Load palletized products into the container or lorry safely.

Load non-palletized products (including cartons and bags) safely into the container or lorry without damaging the products.Oral Assessment



XX

CE26 Secure Cargo for TransportSS37 Techniques to Secure Cargo for Transport. Secure the palletized products in a container/lorry after loading them.

Secure the non-palletized products in a container/lorry after loading them.Practical Assessment


CE27 Complete Documentation to release DriverSS38 Types of Releasing Documentation. Identify the documents used for releasing the driver with the cargo.

Oral Assessment

XX

5Warehouse Operations Training Matrix LKA-LOG-100 (Tupperware Indo).docx