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CLICK TO ADD TITLE. The 5th Global Health Supply Chain Summit November 18 -20, 2013 Addis Ababa, Ethiopia. Warehouse in a Box Project Arno Haigh. [SPEAKERS NAMES]. [DATE]. Warehouse-in-a-Box - Background.

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The 5th Global Health Supply Chain Summit

November 18 -20, 2013Addis Ababa, Ethiopia

Warehouse in a Box Project

Arno Haigh



Warehouse in a box background
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 background1
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
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-to-use , 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 wib1
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
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:

Warehouse in a box what are the steps in installing a wib
Warehouse-in-a-Box – What are the steps in installing a WiB?

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

A suitable size of land needs to made available

Secure utilities & services ( water & electricity)

Warehouse in a box what are the steps in installing a wib1
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 wib2
    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 wib3
    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 – Photographic display of Phases WiB?

    2: Foundations and stud columns

    3: Installation of steel frame

    1: Site selection

    4: Application of cladding to steel frame

    5: Concrete Slab

    Warehouse-in-a-Box – Photographic display of Phases WiB?

    8: Completed pre-fabricated warehouse

    6: Completed warehouse shell

    7: Installation of kitting

    Warehouse in a box training programme
    Warehouse-in-a-Box – Training Programme WiB?

    • 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 programme1
    Warehouse-in-a-Box – Training Programme WiB?

    • 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 lessons learnt
    Warehouse-in-a-Box – Lessons Learnt WiB?

    • 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
    Warehouse-in-a-Box – Proven Results WiB?

    • 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
    Warehouse-in-a-Box – Pending Projects WiB?

    • 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