Every year, as the monsoon clouds gather across India, supply chains brace themselves. For consumers, rains bring relief from scorching heat. For warehouses and logistics managers, however, they bring a recurring season of disruptions, risks, and tough choices.
Why Monsoons Are a Supply Chain Event, Not Just a Weather Event
Unlike one-off disruptions, monsoons are predictable—but rarely predictable enough in intensity or impact. The rains cut across transportation, warehousing, and last-mile delivery, often exposing weak links in supply chain design.
Common Challenges During Monsoon Season
1. Waterlogging Around Warehouses
- Poor drainage can delay vehicle movement and loading/unloading
- Even a few hours of delay disrupts delivery SLAs.
2. Moisture & Humidity Damage
- Electronics, paper-based goods, and packaged food items are at high risk of moisture seepage.
- Wooden pallets swell, cardboard cartons collapse, and rust creeps into MHEs.
3. Transport Bottlenecks
- Flooded highways, delayed rail freight, and grounded flights extend lead times.
- Regional lockdowns or diversions worsen planning accuracy.
4. Workforce Availability
- Attendance dips as employees face travel challenges. In some regions, agricultural activities during monsoon also pull manpower away from warehouses.
5. Last-Mile Delivery Failures
- Motorbikes and small delivery vans struggle in waterlogged city streets.
- Failed deliveries mean reverse logistics load spikes.
How Warehousing Leaders Mitigate Monsoon Risks
- Infrastructure Readiness → Elevating warehouse flooring, sealing roof leaks, waterproof paint, and advanced drainage systems.
- Moisture Control → Use of dehumidifiers, silica gel packs, shrink-wrapping, and plastic pallets instead of wooden ones.
- Buffer Inventory → Storing safety stock closer to key demand centers to hedge against transport delays.
- Technology & Visibility → WMS-driven real-time alerts help reroute shipments or reassign orders when delays occur.
- Transportation Planning → Partnering with multiple carriers and creating alternate route maps.
- Workforce Management → Flexible shift planning and incentivizing attendance during peak disruptions.
A Broader Supply Chain Lesson
The monsoon is India’s annual stress test for supply chains. Companies that prepare with proactive warehouse planning, risk-mitigating infrastructure, and real-time technology resilience not only survive the season but also emerge stronger.