CLICK TO ADD
TITLE
The 5th Global Health Supply Chain Summit
Warehouse in a Box Project
Arno Haigh
[SPEAKERS NAMES]
November
18 -20, 2013[DATE]
Addis Ababa, Ethiopia
Warehouse-in-a-Box - Background
In 2010, the Government of Tanzania (GoT) and USAID discussed the
country’s chronic lack of supply chain infrastructure.
These included -
• Limited storage space.
• Lack of quality storage facilities impacting GoT’s ability to provide
access to health commodities and services to patients.
• Poorly constructed, maintained or managed facilities putting products
at risk of damage , diversion or expiry.
USAID, through implementing partner SCMS, proposed to the GoT an
unprecedented project to install pre-fabricated warehousing units
(warehouse-in-a-box or WiB) in three initial locations in Tanzania.
Warehouse-in-a-Box - Background
Further collaboration with the Global Fund has seen the authorization
of two additional warehouses and the extension of the original 3
warehouse units.
Imperial Health Sciences (IHS) were appointed the sub-contractor by
SCMS to manage and deliver the WiB projects.
Warehouse-in-a-Box – What is a WiB?
•
The WiB facilities is a turnkey solution which includes:
• Infrastructure
• Equipment
• Skills transfer for rapid erection of a fully functional , ready-touse , pharmaceutical warehouse and operational service
• WIB comprises of pre-engineered modular components and
fittings that can be erected quickly and easily and can be fully
maintained and operated by local personnel
• Long term scalability is made possible through the modular
design , which is readily adjustable to encompass future growth
demands
Warehouse-in-a-Box – What is a WiB?
• The design and the configuration of all warehouse modules are
based on fundamental process flows , providing a replicable
and scalable solution
• Standards and operational benchmarks are aligned with
International Supply Chain Principles
• WIB includes all required Materials Handling Storage &
Equipment (racking, forklifts, cages, conveyors, pallet-jacks)
• All office and security equipment
• A complete set of ISO-certified SOP’s to ensure warehouse
staff adhered to International Best Practices
• On the job staff training
• Post installation audit
Warehouse-in-a-Box – Schedule of
Facilities of GoT
•
Below is a schedule of the facilities, the sizes , pallet locations and
dates of completion for the Tanzania WiB project:
Facility
Size
Pallet
Locations
Date of
Handover
Keko
5717m²
6204
June 2012
Mbeya
5655m²
6510
Aug 2012
Dodoma
5729m²
5844
Sep 2012
Tanga
2366m²
2455
Under
Construction
Tabora
2416m²
2512
Under
Construction
Warehouse-in-a-Box – What are the steps
in installing a WiB?
• A suitable size of land needs to made available
• Secure utilities & services ( water & electricity)
Macro Phases
Phase 1: Groundwork Foundation and Substructure
Phase 2: Civil Works
Phase 3: Assembly of Steel Structure and Insulated Panels
Phase 4: Kitting
Phase 5: Training
Result: Full kitted and operational warehouse
Warehouse-in-a-Box – What are the steps
in installing a WiB?
• Phase 1: Groundwork Foundation and Substructure
• Review the selection of land to ensure that the site is suitable
for the installation of the WiB
• Determine scope of work for column foundations , compacting
of ground, pouring of concrete slab , drainage , sewerage and
electrical connections
• Phase 2: Civil Works
• Selection of In-Country engineers and civil contractor
• Developing and issuing of building plans for issuing to local
authorities
• Preparing the site for the assembly of the WiB by installing
temporary facilities such as water and electricity and site office
Warehouse-in-a-Box – What are the steps
in installing a WiB?
• Phase 3: Assembly
• Steel structure
• Insulated Cladding
• Roof
• Phase 4: Kitting
•
•
•
•
•
•
•
Air – Conditioning
Steel Pallet Racking
Materials Handling ( MHE) equipment
Generator
Lighting
Fridge
Offices , Security Control Room & Ablutions
Warehouse-in-a-Box – What are the steps
in installing a WiB?
• Phase 5: Training
• Consists of three modules:
• Supply Chain Management
• Quality Assurance
• Warehouse Operations Management
• Project Management by Imperial Health Sciences – IHS.
•
•
•
•
•
•
•
Comprehensive Project Plan
Risk Matrix
Project task list
Communication plan
Project Charter
Weekly Dash Board
Quarterly Reports
Warehouse-in-a-Box – Architectural View
Warehouse-in-a-Box – Photographic
display of Phases
1: Site selection
2: Foundations and stud columns
4: Application of cladding to steel frame
3: Installation of steel frame
5: Concrete Slab
Warehouse-in-a-Box – Photographic
display of Phases
6: Completed warehouse shell
7: Installation of kitting
8: Completed prefabricated warehouse
Warehouse-in-a-Box – Training Programme
• The comprehensive training programme involves:
• Quality management systems aligned to the operation.
• Full set of customized Standard Operating Procedures –
SOP’s
• Operational training on all processes
• Job description creation, organogram and warehouse
mapping
• MHE training and licensing
• Health & Safety training
• Security training and evaluation for the site and operation
• WHO – Good Warehousing Practice ( GWP) training
Warehouse-in-a-Box – Training Programme
• Check lists and self-audit program for continuous
improvement
• Procurement overview
• Distribution and chain of custody training
• Commissioning & training on all key equipment installations
including maintenance requirements and local
supplier/service identification:
•
•
•
•
•
Racking
Air – Conditioning
Generator
MHE
General maintenance of the site and housekeeping
Warehouse-in-a-Box - Pictorial Keko
Warehouse-in-a-Box - Pictorial Keko
Warehouse-in-a-Box - Pictorial Keko
Warehouse-in-a-Box - Pictorial Keko
Warehouse-in-a-Box - Pictorial Mbeya
Warehouse-in-a-Box - Pictorial Mbeya
Warehouse-in-a-Box - Pictorial Mbeya
Warehouse-in-a-Box - Pictorial Mbeya
Warehouse-in-a-Box - Pictorial Dodoma
Warehouse-in-a-Box - Pictorial Dodoma
Warehouse-in-a-Box - Pictorial Dodoma
Warehouse-in-a-Box - Pictorial Dodoma
Warehouse-in-a-Box – Lessons Learnt
•
Significant commitment from all stakeholders - WiB projects are
time and resource-intensive and require collaboration and
coordination of committed stakeholders
•
Government collaboration - a WiB project consists of activities such
as land identification, environmental impact assessment, availability
of municipal facilities and approval (water, electricity, building
inspection), groundwork's, installation, kitting and staff training
•
Project Management Team (PMT) - without collective Political Will
of stakeholders, such an ambitious project would be not be
successful
Warehouse-in-a-Box – Proven Results
•
These donated WiB’s incur no monthly rental costs to GoT, saving
about $1 million per annum in rental costs. The overall payback period
of rental savings versus the warehouse cost is about 3.5 years. Final
cost savings are estimated to exceed $3 million
•
Pallet positions available before were 12400 positions in 2009.
Positions have tripled to 36629 representing a 195% increase in
capacity with only a 60% increase in area
•
To ensure that the potential from the new warehouses is fully
achieved , 440 GoT (MSD) warehouse personnel have been
certified after attending training courses offered through the WiB
roll-out
Warehouse-in-a-Box – Pending Projects
•
Other WiB projects are currently under discussion with SCMS
countries:
•
•
•
•
Nigeria – two WiB facilities
Democratic Republic of Congo – one facility
Rwanda – one facility
Cote D’Ivoire – one facility
Thank you – Arno Haigh