A

PROJECT REPORT
ON

A STUDY OF CONCEALED CORNERSTONE FOR

GEARING-UP IN FORD MOTORS WHM: THE CLOUDSUITE
AND MODULA WAREHOUSE AUTOMATION
SUBMITTED TO
SAVITRIBAI PHULE PUNE UNIVERSITY
IN PARTIAL FULFILMENT OF THE COURSE
BACHELOR OF BUSINESS ADMINISTRATION
BY
Aaryan Priyal Vedpathak
SEAT NO: 239
B.B.A.- IB Sem-III

UNDER THE GUIDANCE OF PROJECT GUIDE

Asst. Prof. Reshma. H. Awati

MARATHAWADA MITRA MANDAL’s COLLEGE OF

COMMERCE, PUNE 302/A, DECCAN GYMKHANA,

PUNE-411004 YEAR 2023-24

 DECLARATION
This is to certify that the project-work titled (TOPIC) has been
completed satisfactorily and submitted in partial fulfillment of
Bachelor Degree in Business Administration of Savitribai Phule
Pune University for the academic year 2023-24 by the following
student of MARATHAWADA MITRA MANDAL’s COLLEGE
OF COMMERCE, PUNE 411004. My intention to understand this
project lies towards enhancing my knowledge in the field of
Marketing Management.

PROJECT GUIDE HOD

PRINCIPAL
Asst. Prof. Reshma Awati Dr. Ashwini Kulkarni Dr. Devidas Golhar

ACKNOWLEDGEMENT
 I would like to express my sincere thanks to the Savitribai Phule Pune
University, Principal- Dr. Devidas Golhar and Marathwada Mitra Mandal’s
college of Commerce for giving me the opportunity to prepare and present this
report.

“There is a good saying that the work is successfully completed if the person
is guided properly at the right time by the right person”, with that the good
opportunities that we receive as well as the efficient supervision and the most
valuable the internal guidance.

Hereby, I would like to express my deep gratitude towards my project guide

Asst. Prof. Reshma Awati, who helped and guided me in project work. Her
encouragement and whole-hearted cooperation throughout the process helped
me in completing the project.

Last but not the least I would like to thank my family and friends for their
encouragement and direct or indirect support in completion of the project.

Aaryan Vedpathak
SY BBA IB

Part A – Research Paper

A STUDY OF CONCEALED CORNERSTONE FOR
GEARING-UP IN FORD MOTORS WHM: THE CLOUDSUITE
AND MODULA WAREHOUSE AUTOMATION

Getting Started:
-Objectives for conducting the survey:
 The researcher was having total 3 objectives for conducting this research. One
was primary & other two were secondary. So, they were as follows:

Primary Objective:

 To investigate the impact of the Cloud-Suite and Modula warehouse

automation on Ford’s WHM.

Secondary Objectives:

1. Evaluate the effectiveness of the Cloud-Suite and Modula warehouse

automation in improving key performance indicators (KPIs) related to the
identified cornerstone.

 Reduced procurement times

 Minimized production line disruptions
 Increased vehicle production
 Improved space utilization
 Enhanced picking speed and accuracy

2. Analyze the potential broader applicability of the findings to other Ford

Motor Company manufacturing facilities or similar industries.

 Scalability of the technologies

 Adaptability to different production lines and components
 Transferability of lessons learned to other manufacturing contexts

Introduction:
 Welcome and get ready to unveil the
hidden cornerstone behind the smooth
functioning of Ford’s WHM!

 Nutshell about Ford Motors:

Ford Motor Company is an American multinational automobile manufacturer

headquartered in Dearborn, Michigan, United States. It was founded by Henry
Ford and incorporated on June 16, 1903. The company sells automobiles and
commercial vehicles under the Ford brand, and luxury cars under its Lincoln
brand. Ford also owns Brazilian SUV manufacturer Troller, an 8% stake in Aston
Martin of the United Kingdom, and a 32% stake in Jiangling Motors of China. It
also has joint-ventures in China (Changan Ford), Taiwan (Ford Lio Ho), Thailand
(AutoAlliance Thailand), Turkey (Ford Otosan), and Russia (Ford Sollers). The
company is listed on the New York Stock Exchange and is controlled by the Ford
family; they have minority ownership but the majority of the voting power1
 Short info about Cloud-Suite WMS & Modula automatic vertical warehouses
:

CloudSuite WMS is a cloud-based warehouse management system from Infor that

combines warehouse fulfillment with embedded labor management and 3D visual
analysis in a unified application. It offers features like appointment scheduling,
batch inventory tracking, order optimization, Omni channel optimization,
seamless automation integration, and easy ERP integration. CloudSuite WMS also
provides real-time visibility, analytics, and reporting to help warehouse managers
make data-driven decisions and improve operational efficiency. CloudSuite WMS
is designed to support complex and dynamic warehouse environments, such as
those in the automotive industry.

othat act as a buffer for production lines. Ford uses Modula’s vertical warehouses
to store and retrieve components needed for manufacturing quickly and
efficiently. The warehouses are integrated with a robot interface that allows an
anthropomorphic arm to pick up the necessary material from the Modula and
bypass the faulty line, thus avoiding stopping the entire production process.

 Implementation of CloudSuite WMS:

Ford implemented CloudSuite WMS in seven European countries to automate the

process of transferring goods at its ten cross-docking centers (known as ODCs) in
2017. The ODCs receive hundreds of truck deliveries a day from local logistics
service providers and deliver parts to the final assembly plants on a just-in-time
basis. The parts are supposed to be stored for no longer than half a day in the
buffer stocks that are placed circularly around the production lines, known as
“marketplaces”. After that they are assembled just in sequence. All ODC
processes are digitized with CloudSuite WMS. The software receives advanced
shipping notes that announce projected deliveries including their scheduling and
quantity. Shippers are notified about the unloading point and the respective time
slots. Upon reception, all delivery notes are scanned and tendered through cross-
docking processes in accordance with the delivery plan. Larger transport volumes
for different final assemblies are divided into several assigned staging zones for
shipping preparation. CloudSuite WMS enabled Ford to track order fulfillment in
real-time, respond proactively to potential supply bottlenecks, and make staff
deployment more efficient for service providers. The software also helped Ford
reduce inventory costs, improve quality control, and increase customer
satisfaction.

Implementation of Modula vertical warehouses:

Modula warehouse automation is a system that uses vertical lift modules (VLMs)
to store and deliver parts as needed during the manufacturing process. Ford
motors implemented three Modula VLMs in its Valencia plant in Spain, where it
produces and assembles vehicles such as the Kuga SUV, Mondeo wagon, S-Max,
Galaxy and Transit Connect Vans.
The Modula VLMs are integrated with robotic arms that handle the engine parts
and deliver them to the production lines. The VLMs also act as buffers in case of
production disruptions, by temporarily storing the parts until the lines are
resumed. This way, the Modula VLMs help Ford motors optimize space, time,
and efficiency in its warehouse management.

Keywords: CloudSuite WMS, warehouse management system, cross-docking,

logistics, inventory, supply chain, Ford, automotive industry, automatic vertical
warehouses, Modula, anthropomorphic arm

Subject Matter:

Our primary agenda is to investigate the impact of implementing a WMS software

like CloudSuite WMS and Modula warehouse management on the efficiency and
effectiveness of Ford Motors' Warehouse Management System (WMS) within its
Western Hemisphere Manufacturing (WHM) operations. We will also study about
vertical lifting modules VLM’s that, how it acted as buffers, storing parts needed
for production and delivering them as required. This prevented line stoppages due
to part shortages, improving overall production efficiency. This may involve
assessing factors such as order fulfillment speed, inventory accuracy, warehouse
space utilization, and labor productivity.

Subsequently we are also going to study about the need of software in WHM and
different types of WMS. What is the crux for synchronizing WMS with an
organization and what revolution it can bring into the smooth functioning of
WHM. How it can help an organization to become more cost-effective and
increase its (ROI) by reducing its operational cost.
Additional to it we are also analyzing key challenges and opportunities associated
with the implementation of a cloud based WMS. This includes examining
concerns about data security, benefits like scalability, flexibility, and real-time
visibility

Warehouse Management Software:

Warehouse management software (WMS) is a software application that helps
manage and optimize the operations of a warehouse, distribution center, or
fulfillment center. WMS can provide features such as inventory management,
order management, labor management, space management, automation
integration, reporting and analytics.
Inventory management: track and control the quantity, location, status, and
movement of goods in the warehouse
Order management: process and fulfill customer orders, generate pick lists,
packing slips, invoices, and shipping labels
Labor management: monitor and improve the productivity, efficiency, and safety
of warehouse workers
Space management: optimize the layout, storage capacity, and utilization of the
warehouse space
Automation integration: connect and coordinate with automated systems such as
barcode scanners, RFID readers, conveyor belts, robots, and drones
Reporting and analytics: provide real-time visibility, insights, and alerts on
warehouse performance, inventory levels, order status, and potential issue
Some examples of Warehouse Management:

Infor WMS : a cloud-based WMS that combines warehouse fulfillment with

embedded labor management and 3D visual analysis in a unified application. It is
designed to support complex and dynamic warehouse environments, such as those
in the automotive industry.

Zoho Inventory : a cloud-based WMS that integrates with Zoho’s suite of online
business applications, such as CRM, accounting, and e-commerce. It is suitable
for small and medium-sized businesses that need a simple and affordable WMS.

LOGIC ERP: a web-based WMS that offers end-to-end solutions for warehouse
operations, logistics, supply chain management, and e-commerce. It is designed to
cater to the needs of various industries, such as retail, wholesale, manufacturing,
and distribution.
Oracle Warehouse Management Cloud: a cloud-based WMS that leverages
artificial intelligence, machine learning, and Internet of Things to enable smart
and adaptive warehouse operations. It is ideal for large and complex enterprises
that need a scalable and flexible WMS.

Bright-pearl: a cloud-based WMS that connects with multiple sales channels,

accounting systems, and shipping providers to streamline warehouse workflows
and order fulfillment. It is designed for fast-growing and omni-channel retailers
that need a comprehensive and integrated WMS.

Fishbowl: a desktop-based WMS that integrates with QuickBooks and other

popular software to provide inventory control, order management, and barcode
scanning. It is suitable for small and medium-sized businesses that need a user-
friendly and affordable WMS.
Benefits of a Warehouse Management System
Benefit 1: Optimized Space and Lower Operating Expenses
Warehouse management systems optimize warehouse flow by analyzing the best
use of floor space based on the task and material characteristics. In the WMS
implementations, the use of space and floor plan analysis is used to determine
how space should be best used and provides opportunities for reducing waste –
waste of premium floor space and waste of time for locating product. This will
also lessen potential cost resulting from excessive material movement, time
consuming placement, and retrieval. By considering the best locations to store
products, as well as materials or equipment, a warehouse can lower its operating
expenses.

WMS solutions can also help maintain material rotation, whether through first-in,
first-out (FIFO), last-in, first-out (LIFO), or first-expired, first-out (FEFO)
practices. Whatever rotation rule is required, the WMS can help the rotation.
Typically, LIFO enables cost-effective use of space, and movement. FIFO or
FEFO can maintain product quality for items from aging out in the warehouse.
Some solutions have additional fuzzy logic so that a slightly relaxed FIFO or
FEFO reduces additional moves, for example: products that expire in the same
month may be considered both eligible to be picked. A warehouse management
system operates with versatility and flexibility, making it easy to form any
necessary adjustments to maintain best inventory floor location selection, choice
of the correct inventory to pick, and help manage physical movement and worker
performance.

Benefit 2: Inventory Visibility

Using a warehouse management system will also provide visibility of accurate,
real-time inventory levels. This enables a company to more securely estimate
supply and avoid backorders, which leads to more satisfied customers. Using
WMS automation with scanning, RFID, or other location tracking methods
ensures the visibility at the location and reduces the non-WMS enabled situations
where inventory becomes forgotten, lost, or misplaced within the warehouse.

Warehouse management systems work in conjunction with the enterprise ERP and
planning functions to provide demand to forecasting functions by sharing precise
information about how certain products are performing. Product demand and
seasonality is reflected as items are transacted and information communicated.
Therefore, with this information, planners can make reliable decisions about
which products to adjust for the company to increase revenue or mitigate losses.
Benefit 3: Effective Labor
Considering workers’ skill levels, their proximity in the warehouse, their
equipment, and available warehouse tasks, a warehouse management system can
better assign the right task to the right person at the right time. Optimization of
travel time within the warehouse is one of the greatest benefits that the WMS can
provide to improved labor utilization. The WMS can focus labor on highest
impact activities while finding the most well-suited laborer to perform a specific
task. Using labor forecasting, the system can assign jobs on a day-to-day basis and
efficiently design schedules. Scanning items during their entry into a warehouse,
as well as throughout their movements, can eliminate the need for work to be
double-checked, saving time and speeding up the recording process. Scanning
improves pick accuracy, reducing mis-picks, thus providing better customer
service. KPIs can also be utilized to analyze staffing, which is important because
labor is often one of the highest costs of warehouse operations. Labor efficiency,
equipment efficiency, and space efficiency are optimized through appropriate
work assignment.
Benefit 4: Traceable Materials
Inventory materials can be easily traced with warehouse management systems
using lot, batch, and serial numbering. Lot/batch numbers indicate the group in
which materials were made, and the serial number identifies an item specifically.
By use of WMS inventory tracking as previously noted, the ability to match
specific lot/batch or serial numbers with incoming receipts and outgoing
shipments allows for full traceability. This ability to trace materials lowers any
potential redundancy, enables accurate inventory planning and allocation, and
provides current retrievable information for either future traceability, service
maintenance, or recall situations.
Benefit 5: Optimized Supply Chain
A warehouse management system optimizes a warehouse’s internal operation
which can then extend to the broader supply chain. Within the warehouse, a
WMS streamlines the entire warehouse process from inbound receipts to outbound
deliveries improving operational efficiencies and reducing costs. Warehouse staff
achieve fast and accurate shipments by reducing or eliminating unnecessary or
non-productive activity. These savings in time and cost coupled with improved
processes and information can then be passed along to internal and external
partners enabling them to improve their own operations. For example, improved
inbound receiving reduces delivery times, enabling delivery partners to better
leverage their equipment and resources and shippers to better manage inventory
levels. Improved data can reduce risk and increase reliability, benefiting
shippers, suppliers and customers. Data can be shared and leveraged back to an
ERP or to a customer, as well as to a TMS (Transportation Management System).
Product can arrive to its final customer more quickly while allowing the partners
upstream to improve planning. Inventory fulfillment service can be aligned to
inventory management; enabling optimized operations while reducing time &
inventory carrying costs.
Benefit 6: Internal Automation Benefit
Warehouse management systems are the enabler to leveraging additional
automation technologies within a warehouse. Mobile devices can automate
internal work assignments and support a transition from paper to electronic work
and activity recording. This simplifies processes which increases ability to scale
and ensures information accuracy. Mobile pairing with the WMS system can
allow the input process to be expanded, as access can be provided through
handheld mobile devices.

Automation supports ongoing improvement in existing operations through

improved strategies. There are many different levels of automation available,
from automated picking and packing, robotics, analytics driven movements and
AI. Warehouse management systems support these strategies by providing the
foundational elements to capture, record and communicate activity. For example,
sensors, barcoding, pick-to-light, voice, and automated carousels can all
increase throughput when integrated to a WMS by monitoring picking and
packing activity. Use of robots and automated conveyors can streamline
operations and reduce bottlenecks.

Benefit 7: Effective Shipment Management providing better Customer

Service
Inbound and outbound planning can be efficiently managed with a warehouse
system that can adjust movements of inventory and equipment. As inventory is
scheduled for arrival, the exact date and time can be optimized, considering
available labor and equipment for storage tasks. There is ability to plan both
receiving dock doors as well as outbound shipping docks with WMS solutions.
Some WMS solutions also connect to transportation management solutions (TMS)
to further optimize the supply chain processes.

Warehouse management systems can also pick and pack products more
effectively, as managers can choose between zone, batch, or wave picking in a
way that lowers any holdup or issues caused by traffic or ineffective employee
locations. These picking efficiency options provide faster customer order cycle
time and thus improve customer relations. Additionally, due to the inventory
tracking and packing options, customers can receive early notification of
shipments and how the materials are coming. The connection of customers with
advanced shipping notices is better enabled with the WMS solution.

Benefit 8: Ongoing Improvement

As a valuable technological tool, warehouse management systems are designed to
enable continuous improvements. The system can be implemented in phases to
allow ongoing updates with newly developed features consistently, keeping
warehouses efficient as they keep up with current changes. This also allows for
the warehouse to incorporate new processes and innovations over time. And, if the
warehouse management system is based in the cloud, it can update
instantly, which can help reduce the need for large, expensive IT teams.
Warehouse management can help companies maximize profitability and alleviate
error. However, the potential obstacles to getting started with a new management
system can be daunting

Types of Warehouse Management System (WMS)

Since every organization is different and for the seamless warehouse management
process, it is essential to select a system that meets their demands. The most
popular kinds of WMSs among the several varieties are as follows:

Standalone Systems

A simple standalone solution would be appropriate for smaller warehouses or

those that don’t want to add new technology to their supply chain operations. For
example, more recent e-commerce companies are still refining their logistics and
supply chain procedures.

A stand-alone system is economical, maintains inventory control, and oversees a

warehouse. Unfortunately, because this technology needs extra software and
equipment to operate the warehouse, a corporation cannot achieve much with it.
As a result, companies that want to grow and need additional technology in the
future may wish to invest in another robust system.
ERP Modules

Software for enterprise resource planning, or ERP, is ideal for growing companies
looking to reduce labor costs, increase productivity, and automate processes.
Robust reporting, several units of measure, many locations and currencies, email
connectivity, limitless file size, and high transaction volume are just a few of the
system’s many notable features. ERPs typically change as the business does.
Examples include barcode scanning, lot tracking, landing cost monitoring, mobile
picking, two-way communication with e-commerce websites, and CRM.

Sadly, the advantages of an ERP system don’t become clear until much later on—
this is an expensive process. Another drawback is that staff education and training
in proper system usage is crucial to the efficacy of an ERP installation.

Employing staff resources is crucial for organizations when choosing which ERP
system to purchase. The heads of operations, finance, and IT, as well as possibly
sales, marketing, and HR, may be involved in this intricate process. Businesses
using labor-intensive methods, such as spreadsheets and mountains of paper
documents, might require the assistance of an integration professional to assist
with the protracted data migration process. Employee resistance is possible when
the leadership team is against these innovative methods and tools.

Modules for the Supply Chain

The art of supply chain management involves delivering the right goods at the
right cost, location, and time. It controls the flow of products and services,
including finished items, work-in-process inventories, and raw materials.

Supply chain modules (SCM) manage the entire supply chain, as opposed to
systems that merely handle storage. Software for supply chains helps with several
functions, including risk assessment and managing supplier relationships,
customers, transportation, material handling, and inventory control. Additionally,
it automates stock management, material purchases, and product cycles. One SCM
platform may house all of your fleet, inventory, and warehouse management
solutions. Larger businesses and third-party logistics providers typically favor
supply chain systems (3PLs).
 Cloud-based Systems

A SaaS-based warehouse management system is referred to as a cloud-based

WMS. Because the entire interface is web-based, users may view it from any
device connected to the internet, no matter where they are.

The company does not require any hardware on-site because program data is
executed and stored on distant servers. The license fee is paid monthly by the
client; no servers or equipment need to be installed or maintained.

Cloud-based warehouse platforms offer numerous advantages, such as seamless

integration and user-friendliness. Because they are hosted on servers and systems
outside of your company, they are far simpler to set up and maintain technically.
Its ability to unite all aspects of a business into a single platform simplifies and
eases users’ work, which is another noteworthy benefit.

Company profile of Ford Motors:

 Founding: 1903
 Founder: Henry Ford
 Headquarters: Dearborn, Michigan, United States
 Industry: Automotive
 Products: Cars, trucks, SUVs, electric vehicles, luxury vehicles (under the
Lincoln brand)
 Market Cap: $51.36 billion (as of October 26, 2023)
 Revenue: $176.19 billion (2022)
 Employees: 173,000 (2022)

Company History

Ford Motor Company was founded in 1903 by Henry Ford and 11 associate
investors. The company is best known for its Model T, which was the first
affordable car for the masses. Ford revolutionized the auto industry with its
assembly line production methods, which helped to make cars more affordable
and accessible.

In the years since its founding, Ford has grown into a global automaker with
operations in over 60 countries. The company has faced its share of challenges,
including the Great Depression and the financial crisis of 2008. However, Ford
has also had many successes, such as the launch of the Mustang and the F-Series
truck, which is the best-selling vehicle in the United States.

Products and Services

Ford offers a wide range of cars, trucks, SUVs, and electric vehicles. The
company's most popular vehicles include the F-Series truck, the Mustang, and the
Explorer SUV. Ford also offers a luxury car brand, Lincoln, which includes
vehicles such as the Navigator and the Continental.

In addition to vehicles, Ford also offers a variety of financial services, such as

auto loans and leases. The company also provides parts and service for its
vehicles.

Recent Developments

Ford is currently in the midst of a major transformation. The company is investing

heavily in electric vehicles and self-driving cars. Ford plans to launch 24 new
electric vehicles by 2025. The company is also working on developing self-
driving technology, and it has partnered with Argo AI to develop a self-driving
taxi service.

Challenges and Opportunities

Ford faces a number of challenges, including competition from other automakers,

such as General Motors and Toyota. The company also faces challenges from new
entrants to the auto industry, such as Tesla. However, Ford also has a number of
 opportunities, such as the growing market for electric vehicles and the potential
for self-driving cars.

How the Modula warehouse automation works for ford motors:

The Modula VLMs are connected to the factory’s ERP system through its
warehouse management system (WMS) solution. This allows the VLMs to
communicate with the production lines and the robotic arms, and to keep track of
the inventory levels and locations of the parts.

 The robotic arms are equipped with sensors and cameras that enable them to
identify and pick the correct parts from the Modula VLMs. The arms can handle
different types of parts, such as engine blocks, cylinder heads, and crankshafts,
with precision and speed.
 The parts are delivered to the production lines by the robotic arms, which place
them on conveyor belts or pallets. The parts are then assembled into engines by
other automated machines or human workers.
 If the production lines are stopped due to any reason, such as maintenance, quality
control, or power outage, the Modula VLMs can store the parts that are not needed
until the lines are restarted. This prevents the parts from piling up on the floor or
being damaged, and also reduces the risk of losing or misplacing them.
 The Modula VLMs can store up to 260 engine blocks in 14 square meters of floor
space, by using the vertical space of the factory. This saves a lot of space
compared to traditional shelving or racking systems, and also improves the safety
and ergonomics of the workers, who do not have to bend, lift, or reach for the
parts.
 The Modula VLMs can also reduce the time and cost of storage operations, by
eliminating the need for forklifts, carts, or manual picking. The VLMs can retrieve
the parts in seconds, and deliver them to the robotic arms or the workers with a
simple touch of a button or a barcode scan. Modula warehouse automation is a
smart and innovative solution that enhances the productivity and quality of Ford
motors’ manufacturing process. It is a perfect example of how vertical shelving
technologies can be integrated with automation systems to create a fully
automated warehouse solution for the automotive industry. 🚗
Purpose of Softwares:

PURPOSE OF THE CLOUD-SUITE WMS IN FORD'

WAREHOUSE MANAGEMENT:
The purpose of the CloudSuite WMS (Warehouse Management System) in Ford’s
warehouse management is to streamline and optimize the storage and delivery of
parts during the manufacturing process. CloudSuite WMS is a cloud-based
solution that integrates with the Modula warehouse automation system, which
uses vertical lift modules (VLMs) and robotic arms to handle the
parts. CloudSuite WMS enables Ford to improve inventory visibility, order
fulfillment, labor productivity, and space utilization in its warehouses 123.
Here is some more information about how the CloudSuite WMS works for Ford:
The CloudSuite WMS is connected to the factory’s ERP (Enterprise Resource
Planning) system through its WMS solution. This allows the CloudSuite WMS to
communicate with the production lines and the robotic arms, and to keep track of
the inventory levels and locations of the parts.
The CloudSuite WMS provides a user-friendly interface that allows the warehouse
operators to monitor and manage the warehouse operations. The operators can
view the status of the orders, the inventory, the VLMs, the robotic arms, and the
production lines. They can also perform tasks such as creating, modifying, or
canceling orders, printing labels, generating reports, and troubleshooting issues.
The CloudSuite WMS uses advanced algorithms and artificial intelligence to
optimize the warehouse operations. It can automatically assign the best locations
for the parts, based on factors such as size, weight, frequency, and demand. It can
also dynamically allocate the parts to the orders, based on the availability, priority,
and sequence. It can also balance the workload among the VLMs and the robotic
arms, to ensure the fastest and most efficient delivery of the parts.
The CloudSuite WMS also provides analytics and insights that help Ford improve
its warehouse performance and efficiency. It can collect and analyze data from the
warehouse operations, such as the inventory turnover, the order accuracy, the
labor productivity, the space utilization, and the equipment performance. It can
also generate dashboards and reports that show the key performance indicators
(KPIs) and the trends. It can also provide recommendations and alerts that help the
operators make better decisions and take corrective actions.
CloudSuite WMS is a smart and innovative solution that enhances the
productivity and quality of Ford’s manufacturing process. It is a perfect example
of how cloud-based technologies can be integrated with automation systems to
create a fully automated warehouse solution for the automotive industry.

PURPOSE OF THE MODULA' VERTICLE LIFTING

MODULES WMS IN FORD' WAREHOUSE MANAGEMENT:
The purpose of the Modula’s vertical lift modules (VLMs) WMS (Warehouse
Management System) in Ford’s warehouse management is to store and deliver
engine parts as needed during the manufacturing process. The VLMs are
integrated with robotic arms that handle the parts and deliver them to the
production lines. The VLMs also act as buffers in case of production disruptions,
by temporarily storing the parts until the lines are resumed. This way, the VLMs
help Ford optimize space, time, and efficiency in its warehouse management123.
Here is some more information about how the Modula’s VLMs WMS works for
Ford:
The Modula’s VLMs WMS is connected to the factory’s ERP (Enterprise
Resource Planning) system through its WMS solution. This allows the VLMs
WMS to communicate with the production lines and the robotic arms, and to keep
track of the inventory levels and locations of the parts.
The Modula’s VLMs WMS provides a user-friendly interface that allows the
warehouse operators to monitor and manage the warehouse operations. The
operators can view the status of the orders, the inventory, the VLMs, the robotic
arms, and the production lines. They can also perform tasks such as creating,
modifying, or canceling orders, printing labels, generating reports, and
troubleshooting issues.
The Modula’s VLMs WMS uses advanced algorithms and artificial intelligence to
optimize the warehouse operations. It can automatically assign the best locations
for the parts, based on factors such as size, weight, frequency, and demand. It can
also dynamically allocate the parts to the orders, based on the availability, priority,
and sequence. It can also balance the workload among the VLMs and the robotic
arms, to ensure the fastest and most efficient delivery of the parts.
The Modula’s VLMs WMS also provides analytics and insights that help Ford
improve its warehouse performance and efficiency. It can collect and analyze data
from the warehouse operations, such as the inventory turnover, the order accuracy,
the labor productivity, the space utilization, and the equipment performance. It can
also generate dashboards and reports that show the key performance indicators
(KPIs) and the trends. It can also provide recommendations and alerts that help the
operators make better decisions and take corrective actions.
Modula’s VLMs WMS is a smart and innovative solution that enhances the
productivity and quality of Ford’s manufacturing process. It is a perfect example
of how vertical shelving technologies can be integrated with automation systems
to create a fully automated warehouse solution for the automotive industry

History of Ford's warehouse management before and after the

implementation of Infor cloud-suite and Modula vertical warehouse
automation:

Ford is one of the world’s leading automotive companies, with a history of over a
century. Ford has been using warehouse management systems (WMS) since the
1970s, when it was the first customer of Logisticon, the pioneer of WMS
software1. Since then, Ford has been constantly improving its warehouse
management practices, to optimize its supply chain and meet the changing
demands of the market.
Before the implementation of infor cloudsuite and Modula vertical
warehouse automation, Ford faced some challenges in its warehouse
operations, such as:
High space and energy consumption, due to the use of conventional racking and
shelving systems, which limited the storage capacity and efficiency of the
warehouse.
Long procurement and picking times, due to the lack of visibility and traceability
of the inventory, which caused delays and errors in the order fulfillment process.
Frequent disruptions and downtime, due to the breakdowns or malfunctions of the
machinery and equipment, which affected the productivity and quality of the
warehouse operations.
After the implementation of Infor cloud-suite and Modula vertical warehouse
automation, Ford achieved some benefits in its warehouse operations, such
as:
Reduced space and energy consumption, due to the use of vertical lift modules
(VLMs), which are automated storage and retrieval systems that use vertical
shelving units and robotic arms to store and deliver the products, to optimize the
space, time, and efficiency of the warehouse operations.
Improved procurement and picking times, due to the use of infor cloudsuite,
which is a comprehensive enterprise-class WMS software that offers features like
appointment scheduling, batch inventory tracking, and order optimization.
Increased reliability and availability, due to the use of Modula warehouse
automation, which is a system that integrates the VLMs with the production lines
and the delivery vehicles, and uses a custom-made WMS software called WMS
Thor, to track the movement and status of the inventory, from the point of origin
to the point of delivery.
In conclusion, Ford has a long history of warehouse management, and has been
using infor cloudsuite and Modula vertical warehouse automation to streamline its
warehouse operations and enhance its competitive edge in the automotive industry
SWOT analysis of Cloud-Suite WMS and Modula Vertical Lifting
Modules implemented in Ford' Warehouse Management Systems:
SWOT analysis of Cloud-Suite WMS and Modula Vertical Lifting Modules
implemented in Ford’s Warehouse Management Systems:
Strengths:
Cloud Suite WMS and Modula VLMs are integrated solutions that streamline and
optimize the storage and delivery of parts during the manufacturing process.
CloudSuite WMS and Modula VLMs improve inventory visibility, order
fulfillment, labor productivity, and space utilization in Ford’s warehouses.
CloudSuite WMS and Modula VLMs use advanced algorithms and artificial
intelligence to automate and optimize the warehouse operations.
CloudSuite WMS and Modula VLMs provide analytics and insights that help Ford
improve its warehouse performance and efficiency.
CloudSuite WMS and Modula VLMs are scalable and adaptable to different
warehouse sizes, layouts, and demands.
Weaknesses:
CloudSuite WMS and Modula VLMs require a significant initial investment and
maintenance cost.
CloudSuite WMS and Modula VLMs depend on reliable internet connectivity and
power supply.
CloudSuite WMS and Modula VLMs may face technical issues or glitches that
could disrupt the warehouse operations.
CloudSuite WMS and Modula VLMs may require training and change
management for the warehouse operators and staff.
CloudSuite WMS and Modula VLMs may encounter compatibility or integration
challenges with other systems or technologies.
Opportunities:
CloudSuite WMS and Modula VLMs can enhance the productivity and quality of
Ford’s manufacturing process and products.
CloudSuite WMS and Modula VLMs can increase Ford’s competitive advantage
and customer satisfaction in the automotive industry.
CloudSuite WMS and Modula VLMs can enable Ford to adopt more sustainable
and environmentally friendly practices in its warehouse management.
CloudSuite WMS and Modula VLMs can facilitate Ford’s innovation and digital
transformation in its warehouse management.
CloudSuite WMS and Modula VLMs can open new markets and opportunities for
Ford in other industries or regions.
Threats:
CloudSuite WMS and Modula VLMs may face competition from other warehouse
management solutions or technologies that offer similar or better features or
benefits.
CloudSuite WMS and Modula VLMs may be affected by external factors such as
regulations, policies, standards, or customer preferences that could limit or restrict
their use or adoption.
CloudSuite WMS and Modula VLMs may be exposed to cyberattacks, data
breaches, or unauthorized access that could compromise their security or
functionality.
CloudSuite WMS and Modula VLMs may be subject to obsolescence or
disruption by emerging or disruptive technologies or innovations that could render
them obsolete or irrelevant.
CloudSuite WMS and Modula VLMs may face legal, ethical, or social issues or
controversies that could damage their reputation or credibility
 Review of literature:
The researcher has collected & interpreted the data from reading various research
papers for gathering more insights

Website Name: Modula

Link: https://modula.us/experience/ford/
And the concealed insight which we unveiled is that:
Case study of how Ford Motor Company, a leading car manufacturer, improved
its productivity and efficiency by using Modula’s vertical lift modules (VLMs) in
its assembly plant in Spain. The VLMs are automated storage systems that store
and deliver engine parts as needed during the manufacturing process. The VLMs
also integrate with robotic arms and the factory’s ERP system to optimize the flow
of parts and reduce interruptions. The website showcases how Modula’s VLMs
helped Ford save floor space, increase storage capacity, and enhance operational
performance.

Research paper named: An Analysis of Warehouse Management Systems

Author name: Akash Rana

Warehouse management systems (WMS) are software applications that enable

businesses to manage and control warehouse operations, including inventory
management, order processing, and transportation management. This research
paper provides an analysis of warehouse management systems, highlighting the
benefits they offer, the challenges associated with their implementation, and the
best practices for efficient and effective use. Warehouse Management Systems
(WMS) are an integral part of modern-day warehousing operations. This literature
review provides an overview of the current trends, challenges, and
opportunities in the WMS field. The review identifies key areas of
development, including the impact of Industry 4.0 on warehouse operations,
the use of artificial intelligence and machine learning in WMS, and the adoption
of cloud-based WMS solutions. The review also highlights challenges associated
with WMS implementation, including the need for skilled personnel,
data security, and system integration. Finally, the review identifies opportunities
for future research, including the development of predictive analytics, the use of
blockchain in WMS, and the implementation of robotic process automation.

Website name: Logistics Manager

Link: https https://www.logisticsmanager.com/ford-implements-cloud-based-
wms-across-europe/
And the concealed insight which we unveiled is that:
Ford Motor Company, a leading car manufacturer, improved its logistics
operations by implementing Infor SCE, a cloud-based warehouse management
system, in its cross-docking centres in seven European countries. The website
explains how Infor SCE helped Ford automate the process of transferring goods
from local logistics service providers to final assembly plants, and how it
increased the efficiency, transparency, and cost-effectiveness of Ford’s supply
chain. The website also provides a testimonial from Michael Weidel, director of
supply chain management at Infor, who highlighted the benefits of cloud
applications for the automotive industry. The website aims to showcase Infor SCE
as a modern and innovative solution for the logistics challenges faced by car
manufacturers.
 Research Methodology:

Research methodology is a way of explaining how a researcher intends to carry

out their research. It's a logical, systematic plan to resolve a research problem. A
methodology details a researcher's approach to the research to ensure reliable,
valid results that address their aims and objectives. It encompasses what data
they're going to collect and where from, as well as how it's being collected and
analysed.
Types of research methodology
When designing a research methodology, a researcher has several decisions to
make. One of the most important is which data methodology to use, qualitative,
quantitative or a combination of the two. No matter the type of research, the data
gathered will be as numbers or descriptions, and researchers can choose to focus
on collecting words, numbers or both.
Here are the different methodologies and their applications:
Qualitative
Qualitative research involves collecting and analysing written or spoken words
and textual data. It may also focus on body language or visual elements and help
to create a detailed description of a researcher's observations. Researchers usually
gather qualitative data through interviews, observation and focus groups using a
few carefully chosen participants.
This research methodology is subjective and more time-consuming than using
quantitative data. Researchers often use a qualitative methodology when the aims
and objectives of the research are exploratory. For example, when they perform
research to understand human perceptions regarding an event, person or product.
Quantitative
Researchers usually use a quantitative methodology when the objective of the
research is to confirm something. It focuses on collecting, testing and measuring
numerical data, usually from a large sample of participants. They then analyze the
data using statistical analysis and comparisons. Popular methods used to gather
quantitative data are:
  Surveys
 Questionnaires
 Test
 Databases
 Organizational records
This research methodology is objective and is often quicker as researchers use
software programs when analysing the data. An example of how researchers could
use a quantitative methodology is to measure the relationship between two
variables or test a set of hypotheses.
Mixed-method
This contemporary research methodology combines quantitative and qualitative
approaches to provide additional perspectives, create a richer picture and present
multiple findings. The quantitative methodology provides definitive facts and
figures, while the qualitative provides a human aspect. This methodology can
produce interesting results as it presents exact data while also being exploratory.

Research Design
Research design refers to the overall strategy or plan for conducting a research
study. It outlines the methods and procedures that will be used to collect and
analyse data, as well as the goals and objectives of the study. Research design is
important because it guides the entire research process and ensures that the study
is conducted in a systematic and rigorous manner.
Types of research design
Exploratory Research
As the name implies, the primary objective of exploratory research is to explore a
problem to provide insights into and comprehension for more precise
investigation. It focuses on the discovery of ideas and thoughts. The exploratory
research design is suitable for studies which are flexible enough to provide an
opportunity for considering all the aspects of the problem.
At this point, the required information is loosely defined, and the research process
is flexible and unstructured. It is used in the situation when you must define the
problem correctly, identify alternative courses of actions, develop a hypothesis,
gain additional insights before the development of an approach, set priorities for
further examination. The following methods are used for conducting exploratory
research
 Survey of concerning literature
 Experience survey
 Analysis of insights stimulating
Descriptive Research
By the term descriptive research, we mean a type of conclusive research study
which is concerned with describing the characteristics of a particular individual or
group. It includes research related to specific predictions, features or functions of
person or group, the narration of facts, etc.
The descriptive research aims at obtaining complete and accurate information for
the study, the method adopted must be carefully planned. The researcher should
precisely define what he wants to measure? How does he want to measure? He
should clearly define the population under study. It uses methods like quantitative
analysis of secondary data, surveys, panels, observations, interviews,
questionnaires, etc.

Data Collection:
Data collection is the process of gathering and collecting information from various
sources to analyse and make informed decisions based on the data collected. This
can involve various methods, such as surveys, interviews, experiments, and
observation.
In order for data collection to be effective, it is important to have a clear
understanding of what data is needed and what the purpose of the data collection
is. This can involve identifying the population or sample being studied,
determining the variables to be measured, and selecting appropriate methods for
collecting and recording data.
Types of Data Collection:
Types of Data Collection are as follows:
Primary Data Collection
Primary data collection is the process of gathering original and firsthand
information directly from the source or target population. This type of data
collection involves collecting data that has not been previously gathered, recorded,
or published. Primary data can be collected through various methods such as
surveys, interviews, observations, experiments, and focus groups. The data
collected is usually specific to the research question or objective and can provide
valuable insights that cannot be obtained from secondary data sources. Primary
data collection is often used in market research, social research, and scientific
research.
Secondary Data Collection
Secondary data collection is the process of gathering information from existing
sources that have already been collected and analysed by someone else, rather
than conducting new research to collect primary data. Secondary data can be
collected from various sources, such as published reports, books, journals,
newspapers, websites, government publications, and other documents.

Research Methodology used in this paper:

Research design

This research has used mixed-method to study by examining other

research papers which is an attribute of descriptive research & the
information or insights taken by conducting survey is an attribute of
explorative study.

Collection of data

The collection of data is done through survey methods. The data were
collected through Primary and secondary sources.

Sources of data collection:

Secondary sources of data collection:
We have sourced data from official website of Modula and Infor & also through
Wikipedia and other trusted websites for making the highest quality of research .
 Bibliography:

Top 8 Benefits of a Warehouse Management System (clarkstonconsulting.com)

Warehouse Management System - Features, Benefits, and Types (cmarix.com)
What is Warehouse Management? Benefits, Processes & Strategies | NetSuite
Warehouse Management System: Importance, ProModula Warehouse Automation for Automotive:
Fordcesses & Benefits (softwaresuggest.com)
 PART – B
A VISIT TO ZEPTO’S WAREHOUSE

Researcher did a short visit to Zepto’ warehouse which is situated at Kothrud.

Zepto is a quick commerce app that delivers online groceries, fruits,

vegetables, personal care, electronics, and more to customers in just 10
minutes. Zepto was founded in 2021 by two 19-year-old Stanford
dropouts, Aadit Palicha and Kaivalya Vohra, who wanted to create a
faster and better online grocery shopping experience
 A PICTURE WITH THE INTERVIEWEE

Name of the interviewee - Ajit Shinde

Role – Shift in-charge
Q.1 What are inbound, process and outbound activities?
The picking is done through a particular area allotted for picking the products.

And then the checking process is done by Cycle counting method. If the products
are defective, short, unscrupulous, they discard & they raise a complaint to the
distributor through e-mail.

The products which have passed the checking process and have got approval are
placed in racks and are stacked vertically shown in the above picture.
For storing fruits and vegetables they have cold storage compartments
For tracking each crate, codification is done
For tracking the stage of every process WMS Thor tailor-made system
is used.
 At the time of delivery there are many shelves allotted to different
locations with QR embedded in them which the delivery deliveryman
has to scan before going for the last mile.
Q.2 What kind of products are stored in the Warehouse?
The warehouse mainly stores grocery products, such as packaged food, beverages,
snacks, and household items. It also stores fresh fruits and vegetables that are
sourced from local farmers and suppliers.
Q.3 How do they keep track of their inventory?
They use a method called Cycle-counting to monitor and update their inventory
levels. This method involves counting a small portion of the inventory every day,
and comparing it with the records in the system. They also perform the inwarding
process, which is the process of receiving and storing the incoming products, at
night from 11:00 PM to 1:00 AM. The warehouse operates round the clock, 24
hours a day.
Q.4 How big is the warehouse and what is its shape?
The warehouse covers an area of approximately 3500 square meters, which is
equivalent to about 0.86 acres. The warehouse has a rectangular shape, with a
length of about 70 meters and a width of about 50 meters.
Q.5 Do they have a separate office area from the warehouse area?
No, they do not have a separate office area from the warehouse area. The office
and the warehouse are located in the same space, without any partitions or walls.
The office consists of a few desks, chairs, computers, and other equipment that are
placed in a corner of the warehouse.
Q.6 What are the modern trends that you have implemented in your
warehouse management?
We have implemented a custom-made WMS (Warehouse Management System)
called WMS Thor, which helps us to track the movement and status of our
inventory, from the point of origin to the point of delivery. We also use QR
(Quick Response) codes and barcodes to track the delivery and product
information, respectively. These technologies enable us to improve our efficiency,
accuracy, and visibility in our warehouse operations.
Q.7 What is the biggest challenge that you face in your warehouse
management?
The biggest challenge that we face in our warehouse management is finding and
retaining the right delivery personnel who can perform the first-mile and last-mile
delivery in a timely and safe manner, while following all the required protocols.
The first-mile delivery refers to the transfer of goods from our warehouse to a
carrier or a transportation hub, while the last-mile delivery refers to the transfer of
goods from a carrier or a transportation hub to the final destination. These are the
most critical and costly stages of the delivery process, and they require skilled and
reliable delivery personnel.
Q.8 How much does it cost to operate and set up your warehouse?
Our operational cost, which includes the expenses for labor, utilities, maintenance,
and transportation, is around 15-20 lakhs per month. Our set-up cost, which
includes the expenses for land, building, equipment, and software, is around 4.76
crores.
Q.9 What method do you use to dispatch your products from your
warehouse?
We use different methods to dispatch our products from our warehouse,
depending on the type and shelf life of the products. For fruits and vegetables,
which are perishable and have a short shelf life, we use the FIFO (First-In, First-
Out) method, which assumes that the oldest products in our inventory are sold
first. This way, we avoid wastage and spoilage of our products. For groceries,
which are non-perishable and have a long shelf life, we use the LIFO (Last-In,
First-Out) method, which assumes that the newest products in our inventory are
sold first. This way, we reduce our inventory holding costs and taxes.
Q.10 Who owns the warehouse and what is their name?
The warehouse is a privately owned warehouse, and the name of the owner is
Kavailya Vohra. He is the founder and CEO of Zepto, a quick commerce app that
delivers online groceries, fruits, vegetables, personal care, electronics, and more to
customers in just 10 minutes. He started Zepto in 2021, along with his co-founder
Aadit Palicha, when they were both 19-year-old Stanford dropouts. They wanted
to create a faster and better online grocery shopping experience for the
customers. Zepto operates in several cities in India, such as Mumbai, Delhi,
Bengaluru, Gurugram, and Chennai, and has raised $60 million in funding from
investors like Y Combinator, Nexus, and Glade Brook. Zepto uses cloud-based
technology and vertical lift modules to optimize its warehouse operations and
delivery efficiency. Zepto claims to have thousands of items on offer and a high
customer retention rate. Zepto is one of the fastest-growing start-ups in the Indian
e-commerce sector, and aims to expand to other markets and industries in the
future

Q.11 How old is Zepto’ Warehouse?

Zepto’s warehouse is relatively new, as it was established in 2021, along with the
launch of Zepto, a quick commerce app that delivers online groceries, fruits,
vegetables, personal care, electronics, and more to customers in just 10
minutes Zepto’s warehouse is located in Mumbai, India, and covers an area of
approximately 3500 square meters. Zepto’s warehouse is 2.7 years old as of
February 2024.
Q.12 How many people are required to manage the warehouse?
Zepto’s warehouse requires a total of 15 people to manage its operations. This
includes one shift in-charge, who oversees the overall warehouse activities and
coordinates with the other staff; two security guards, who ensure the safety and
security of the warehouse premises and the goods; 10 workers, who perform the
tasks of receiving, storing, picking, packing, and loading the goods; and two
quality and safety officers, who monitor and maintain the quality and safety
standards of the warehouse and the goods.
Q.13 What are the safety protocols followed in the warehouse?
Zepto’s warehouse follows strict safety protocols to ensure the well-being of its
staff and customers. Some of these protocols are:
Entry of any outsider is prohibited in the warehouse, and if allowed, they are
thoroughly checked and screened for any potential risks or threats.
All the staff are required to wear compulsory gloves and caps while working in
the warehouse, to prevent any contamination or infection of the goods.
All the staff are trained and certified in the proper use and handling of the
warehouse equipment, such as forklifts, pallet jacks, and scanners.
All the goods are stored and handled according to their specific requirements,
such as temperature, humidity, and shelf life. For example, fruits and vegetables
are stored in cold storage compartments to preserve their freshness and quality.
All the goods are checked and verified for their quality and quantity before and
after the picking process, using a cycle counting method and a WMS Thor system.
All the goods are packed and labeled with QR codes and barcodes to track their
delivery and product information, and to ensure their accuracy and security.
Q.14 What is the process for picking the goods in the warehouse?
Zepto’s warehouse uses a zone picking method for picking the goods in the
warehouse. This method involves dividing the warehouse into different zones or
sections based on various characteristics such as item category or picking
requirements. Each zone has its own location for storing or retrieving the goods,
and each picker is assigned to a specific zone. The picker only picks the items
from their assigned zone to fulfill the orders, and passes them to the next zone or
the packing area. This way, the zone picking method reduces the travel time and
congestion of the pickers, and improves the efficiency and accuracy of the picking
process.