WAR-020 Dispatch of Goods From Warehouse

1. Movement of Finished Goods from Production to Warehouse Quarantine

1.1. See (SOP WAR-040).

2. Dispatching Finished Goods from Quarantine

2.1. The Warehouse receives a Finished Goods Shipping Form (Form-550) from distribution team which indicates (in Part A) Date to be shipped, Finished Goods Code, Shipping Number, Product Description, BPN numbers, number of pallets, GBS number, pallets location in Quarantine, invoice number, Total quantity, Address to be sent and Transportation mode.

2.2. Warehouse authorised staff has to pick the goods from its correct location (Quarantine) and check the followings:

 – The shipping form is signed by an authorised supply person.

 – All pallets have ‘RELEASED’ Stickers prominent to each side of the pallet.

 – Product code, name and description are matching with the shipping form.

 – Pallet ID card is present on each pallet.

 – Check GBS number is matching with that of pallet ID.

 – Senders address and invoice number is present on the form.

2.3.         Warehouse staff to write the following from the pallet ID cards:

 – Product code

 – Product name

 – BPN

 – Number of pallets

 – Total quantity of goods

 – GBS number (as written on the pallet ID card)

2.4. Warehouse staff who assembled the pallet/s must sign on the shipping form. Another authorised store person has to check the pallets to be shipped and sign the form.

3. Documentation

It is important that all goods leaving the Receiving Store should be properly documented so as to enable easy reference.

3.1. Completed and signed Finished Goods Shipping Form (Form-550). One copy of the completed form will be kept in the warehouse office. The original will sent to the Distribution team.

3.2.‘Shipping Note’ book

Shipping note book is a log kept in the warehouse office. Required details are to be filled up form the shipping forms:

 – Shipping number

 – Customer account number

 – Product Code

 – BPN

 – Number of pallets

 – Total quantity of goods

 – Total Weight

 – Signature of Driver

 – Signature of warehouse staff

 – Registration number of vehicle.

4. Pallet Shrouding

4.1. Material

Shrouding involves enclosing the finished goods pallet in cardboard for protection and in readiness for export.  There are several separate cardboard sections that combine to totally shroud a pallet.  These are:

 – Bottom tray is a cardboard base on which the shroud and Finished goods are placed.

 – Side Shroud is a one-piece sheet of cardboard with defined sections for bending.  They are designed to be bent into place and placed on top of the bottom tray, standing up covering the goods on the pallet. The side shroud covers three sides and wraps around the fourth with two small bends.  The front pad fits into these bends completely shrouding the sides of the pallet.

 – Front Pad is a plain piece of cardboard designed to slip between the bended ends of the side shroud.  The bended ends of the side shroud hold the Front Pad in place.

 – Top Tray is a single piece of cardboard with bends at the edges, which are stapled together. This is placed over the top of the pallet.

 – Corner Boards – these are thick pieces of cardboard designed to be placed on the top corners of the top tray to prevent the Finished goods from being crushed when polystrapped.  This also prevents the shrouding from being crushed.

 – Polystrapping is plastic strapping used to secure the shrouding in place.

 – Staples are used to fix the corners of the top trays together.

4.2. Procedure:

All export pallets must have bottom trays.

All Export pallets must be slip sheeted onto the appropriate pallet.

Once slip-sheeted, place the pallet on Wrapper – add corner boards to ALL Pallets and then re-wrap the whole pallet using the pallet wrapper to ensure finished goods do not move in transportation.

Make sure that the Finished goods and the bottom tray is properly orientated on the pallet.  If the Bottom Tray interlocks do not lock in use the stapler to interlock them.

Check to make sure that the goods are on the pallet are wrapped securely and all Corner Boards are applied before shrouding.

Remove the pallet ID and send it back to warehouse office.

Place Side Shroud around the Finished goods on top of the bottom tray.  Each cardboard sheet has several folds, which must be bent, into place around the pallet.

Place Front Pad on end of pallet between the short folds of the side shroud.

Assemble Top Tray by bending folds into place and stapling them together with the compressed air staple gun.

Place Top Tray on pallet over the Side Shroud and Front Pad.

Place Corner Boards on the top edges of the top tray.

Secure shrouding with two strips of Polystrapping using the Fromm Polystrapper.

The pallet is now ready to be written up on the shipping for (Form-550) and loaded onto a truck when it arrives.

5. The Fromm Polystrapper

The Fromm Polystrapper (Figure 1) is a hand held portable device designed to place tension on plastic straps and then heat glue the straps together.  It is important to make sure that the Polystrapper is operated correctly to ensure a good seal of the straps.

Figure 1 – The Fromm Polystrapper

5.1. Operation:

Once the Pallet is shrouded, run the strapping plastic under the pallet at one end.

Place Corner Boards on the corners of pallet on the Top Tray.

Gather straps from both sides of the pallet on top of the pallet.  You should have the strap going completely around the pallet.

Overlap the straps with end on the bottom and sqeeze the handle on the Polystrapper, placing the overlapped section of the straps in between the Polystraper jaws.  These are towards the bottom of the device.

Once in place and straight, let go of the handle and push the Yellow button on top of the Polystrapper (see Figure 2).  The straps should pull tight as the Polystrapper pulls each strap through the device.  Press the button until a reasonable amount of tension is placed on the straps.

Figure 2 – shows Tension button operation

Figure 3 – shows Heat Seal/Strap Release lever

6. Flick the Yellow lever (Figure 3) completely over until the Yellow light on the back of the Polystrapper turns Orange.  This will heat seal the straps together and cut the remaining end of the strap to allow it to be cleared from the device.  Pull the top piece of strapping away immediately and replace the Yellow lever to its original position.
7. Squeeze the handle on the Polystrapper again to release the device from the straps.  Shift the Polystrapper sideways to the right and remove it from the straps.
8. Repeat the above procedure at the other end of the pallet.

         Figure 4 – Finished Shrouded Pallet.

6. Compressed Air Stapler

The Compressed Air Stapler is used to staple the corners of the top trays together so it fits over the shroud on a pallet.

Figure 5 – Staple Gun

6.1. Procedure for Operation and Maintenance:

6.1.1. The Compressed Air Stapler is attached to a portable air compressor that powers it.

6.1.2. Before using the Stapler, you must first check that the leads are not frayed or cut, the connection to the air compressor is intact, and the power is turned on at the wall.

6.1.3. Fold corners of top tray.  Tuck one behind the other at the fold line. Place stapler face down over folded corners and press the trigger.  Take care not to put fingers directly behind the staple zone underneath the cardboard.  The corners should be stapled together.  Place two staples in each corner to make sure the corners hold together.

Figure 10 – Fold corners over

Figure 11 – Staple corners together

6.1.4. Repeat for each corner until all corners are securely stapled together.

6.2. Filling Staple gun with staples

6.2.1. Detach gun from compressor hose before reloading with staples.

6.2.2. Press down on magazine cover release and slide backwards to expose the staple magazine space.

Figure

6.2.3. Place staples in the magazine space and slide the cover back over the magazine space until cover clicks into place.

6.2.4. Reattach gun to the Compressor hose.  The gun is now ready to use.

6.3. Maintenance

6.3.1. Once a day remove gun from compressor hose and place two drops of oil into the air inlet piece on the gun itself.

7. Summary of Changes