Warehouse Controller

Job Description

RCL FOODS is searching for a Warehouse Controller to join the Milling Division. The role will be based in Pretoria and will report into the Customer Service Excellence Manager.

The Warehouse Controller will be responsible manage the warehouse stock integrity and ensure the effective internal distribution and replenishment.

Duties & Responsibilities

Operational Warehouse Management:

• Warehouse shift sizing conducted & resources aligned to weekly & daily activity.
• OPex budgeted / FE costs understood vs actuals. Costs reviewed; gaps identified with action plans implemented.
• Develop and continuously validate SOP’s through management routines by using tools and ensure understanding by all warehouse employees (OWD).
• Conduct 5’s Audits, consolidate results and use management tools to improve results.
• Use problem solving tools e.g. 5 WHY, Abnormality Reports, SIC, OPLs, RACI’s, OWD’s, PDCA’s, etc, to develop action plans to show improvement on PI’s and KPI’s.
• FLT damages reported and action taken for abuse.
• Daily review of OB entries and action taken thereafter.
• Daily Load plan execution, 100% with deviation reported to management and action plan to rectify.
• SCTs received and closed daily.
• Stock deployment as per ABC analysis and bin strategies.

Inbound Control:

• Ensure the effective control of the inbound process, e.g. quality checks, driving solid put away strategies, compliance to system movement requirements, etc.
• Activate internal material movement, incorporating placing the order; picking the product and moving it to truck for despatch.
• Control First Expiry First Out management through the inbound and outbound movements.

Outbound Control:

• Control the functions of outbound, ensuring the correct products are despatched promptly out to the customer.
• Ensure that all orders are leaving the warehouse correctly packed and damage free.
• Ensure that all invoicing is completed accurately and make necessary corrections where required.
• Facilitate the process of loading goods onto trucks and where applicable ensure they are sealed for transport to the customers.
• Track outbound customer service failure trends related to Logistics, establish root causes and take the appropriate corrective action, e.g. damages, late dispatches, incorrect loading, etc.
• Track and measure the PI of the loading/unloading bay allocation tool with action plans to improve productivity.

Stock Control:

• Ensure stock is in the right location by completing cyclic counts on a daily basis.
• Control damages on inbound/outbound and track trends.
• Proactively manage stock age, slow moving and obsolete stock across all stock holding points and make recommendations to clear stock for the categories being managed.
• Monitor shelf life to ensure staff are doing proper stock rotation using the FEFO (First Expiry, First Out) system.
• Independent inventory count is recorded accurately with quantities & BBD x SKU & bin cards clearly displayed as per SOP standards.
• Identify the root cause of inventory count variances and put action plans in place through problem solving tools to improve the Inventory accuracy KPI.
• All physical movements of FG Inventory are transacted in SAP accurately. Inbound & Outbound movements, Production receipts validated by 3-point checks as per Audit requirements.
• Adherence to warehouse layout, ABC plan & traffic flow aligned to warehouse activities e.g. return zone; Order Picking zone; Repack zone; Finished Goods zone.
• Ensure movement of materials reflects in the SAP system at all times.
• Create and manage warehouse management tools to ensure FIFO.
• Track and trend ABC compliance to realise warehouse efficiencies, Time and Motion studies and show results evolution.
• Monthly Inventory reconciliation.

Warehouse Maintenance:

• Ensure the warehouse is kept clean by inspecting the various areas.
• Ensure the appropriate physical segregation and labelling of damaged goods.
• Check that lighting is adequate, doors open and close easily amongst other specifics that impact productivity.
• Report areas/issues in need of attention to the respective Maintenance Manager.
• Ensure that all bin allocations are clear of any obstruction.
• Ensure all forklifts are in good working order.
• FLTs checklist are submitted daily.

Security Control:

• Ensure that all stocks leaving the warehouse premises do so with accurate documentation.
• Instruct security to check staff when they leave or enter the premises.
• Ensure that all trucks leaving the warehouse are correctly documented.
• Ensure adherence to all relevant security protocols.

Standards/Compliance Adherence:

• Ensure goods are delivered in the appropriate condition and that there is no damage or discrepancy.
• Verify that a new load always enters a clean and well-maintained vehicle, highlighting the significance of quality.

Improve Quality Standards:

• Manage, track and trend such as: warehouse cleanliness, pest control schedule adherence, cross contamination from non-food grade chemicals, daily temperature control and product exposure.
• Implement and adhere to a Location-Based Inventory System to identify stored product.
• Ensure compliance to the freshness & rotation policy as per SOP standards.
• Ensure adherence to blocking standards on non conforming inventory.
• Product quality induction programme conducted.
• Track, trend and manage repacking operation to conform to quality standards and to improve repacking productivity.
• Execute Action Plan to address the Stock Age Index KPI.
• Create a quality induction programmed ensure 100% compliance on training to warehouse staff.

Team Supervision:

• Train staff on the Standard Operating Procedures that serve to guide their approach to work. Ensure that staff understand the procedures and sign off the relevant documents.
• Implement the Standard Operating Procedures through consistent application and communication.

Minimum Requirements

• Must have a National Diploma or Degree in Logistics.
• Computer literacy (MS Office).
• At least 3 years of experience in a warehouse environment.
• SAP/Syspro system experienced required.

Knowledge:

• Sound knowledge of warehousing, distribution and planning.
• Warehouse based business processes and practices.
• Warehouse methodologies and principles.