Team 1:
AWO FW 46 “I empower this team to follow the guidelines of Action Workout and support all decisions that are made by the team.”
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Jeffersonville Warehouse Bounce Reduction
Robert Wooldridge,
Warehouse Mgr.
Date: 11-13-2007
TE AM
PI C
TU
R E
Team Members
Tom Elrod
Transportation
Chad Filek
IQ manager
Terry Bale
Operations
Tim Wyatt
Turret Team Leader
Rita Moses
IQ
Jay Shepherd
Pick associate
Tom Ording
Black Belt
Mike Frohme
King of IT
Jeffersonville Warehouse Bounce Reduction Goals &
Team 1:
Objectives
•Eliminate bounces in the bulk area Aisle 70 •Eliminate bounces in the door area Aisles 53-56
Jeffersonville Warehouse Bounce Reduction
Team 1:
Bounce Rate by Week and Type 7.0% 6.0% 5.0% 4.0% 3.0% 2.0%
200742
200741
200740
200739
WH Bounce 200738
200737
Picker Bounce 200736
200734
200733
200731
200730
0.0%
200732
Total Bounce
200735
1.0%
Jeffersonville Warehouse Bounce Reduction
Team 1:
Pareto of Bounce by Item Type
WB31
WH45
WR02
WD12
WD21
WR71
WB62
WR12
WR55
WH20
WB07
WB36
WR32
WR60
WH12
WR24
WB56
WR17
WR78
WB27
8.0% 7.0% 6.0% 5.0% 4.0% 3.0% 2.0% 1.0% 0.0%
Jeffersonville Warehouse Bounce Reduction
Team 1:
I Bo nve nt un or ce y in sh ac ip cu co ra C m cy on pl et so e lid or at de io r n Pr oc es Ite s Ite m m hi dd ID Lo s en s M no t r ov et tv e ur Pa is Ph ne ib rts le d ys in m ic a w al te ro ly ria n b g Ite l ef lo or m ca e in tio Sy no n st nem pi ck ic al ab ly le lo ca Ai sl tio e n In b co lo ck Lo nv e st en sm d * ie nt al pi ck l pa rts co nd R ec itio ei n vi * ng m ov es Sp id er s *
Jeffersonville Warehouse Bounce Reduction 40 35 30 25 20 15 10 5 0
Team 1:
Count
* Non-measurable occurrences
Jeffersonville Warehouse Pugh Concept Selection Matrix Bounce Reduction
Team 1:
Criteria Safety Operator Safety Traffic Sprains/Strains Quality Number of handles Pick accuracy / order accuracy FIFO Inventory accuracy Bounce rate Delivery Pick cycle time Pack cycle time Cost Lines per hour Implementation cost Implementation time Transportation Sum of Positives Sum of Negatives Sum of Sames Weighted Sum of Positives Weighted Sum of Negatives
Rating
Pick All Orders Same Day WMS Directed Replenishment Single Pickable Locations by SKU Remortgate Inventory Process Allow Directed Pick (multiple locs) Improved Consolidation Allocated order visability
Concepts Note: Pick one concept as the "Datum" or Baseline Concept
5 3 4
S S S
S S
S + S
S S S
S + S
S S S
S S S
3 4 1 4 5
+ S S S
S S S -
+ S + +
S S + S
S +
+ S + -
+ S + S
4 4
+ S
S S
S S
S S
S S
S S
S S
4 4 3 4
S + S 3 1 9 11 4 7
+ S 1 4 8 4 15 -11
+ + 6 2 5 24 7 17
+ S S S 2 0 11 8 0 8
+ + 4 4 5 15 16 -1
+ + + 5 2 6 19 9 10
S + + S 4 0 9 15 0 15
Jeffersonville Warehouse Bounce Reduction Operation
Picking
Problem
Outer wall bays contain a lot of bugs and spiders, making picking a challenge Before Kaizen
Team 1:
Actions Taken
Results
Exterminator called to clear bins. List of effected bays created in Pick Central for future identification
Pickers will not be reserved about reaching into locations
After Kaizen
Jeffersonville Warehouse Bounce Reduction Operation
Picking
Problem
Proper tools to break down overpack situations not standard on picker trucks. Before Kaizen
Driver's compartment Seat Belt\Harness attachment Windshield - clean Horn Lift Control - raise to check Side Shift Control Tilt Control
Team 1:
Actions Taken
Results
Tool list added to Daily Checklist for operators.
More likely to be able to pick banded or shrink wrapped items.
After Kaizen
Driver's compartment Seat Belt\Harness attachment Windshield - clean Horn Lift Control - raise to check Side Shift Control Tilt Control Box Cutter Clipboard Tape Gun
Jeffersonville Warehouse Bounce Reduction Operation
Picking
Problem
Locations on bin labels in aisles 53 – 55 are covered by shelving wire mesh. Before Kaizen
Team 1:
Actions Taken
Results
Redesigned and relabeled over 1,200 door locations including check digit.
Locations much easier to read, which should result in fewer bounces.
After Kaizen
Jeffersonville Warehouse Bounce Reduction Operation
Picking
Problem
Inventory stock outs in blue bin area are not visually identified.
Before Kaizen
Team 1:
Actions Taken
Results
Flip all empty blue bins after pulling final part. Added the instruction to SOP.
Better organization leads to fewer bounces.
After Kaizen
Jeffersonville Warehouse Bounce Reduction
Team 1:
Operation
Problem
Actions Taken
Picking
Inventory in blue bin area inaccurate.
Ran test aisle-proofing to validate error rate and identify most common causes. 27% error rate.
Before Kaizen
Results
Improved inventory accuracy in aisleproofed blue bin locations.
After Kaizen
Parts in brown box
Mislabeled parts
Missing location label
Parts on floor
Mislabeled bin
No label on bin
Missing parts bin
Empty misplaced bin
Bin of non-inventoried parts
Non-inventoried parts
Jeffersonville Warehouse Bounce Reduction Team 1:
Failure mode in blue box area
Jeffersonville Warehouse Bounce Reduction Operation
Picking
Problem
Consolidation process causes inventory to move during print-pick window. Before Kaizen
Team 1:
Actions Taken
Results
Consolidated doors (high bounce category) into single, expanded bay locations.
Will need to track to measure reduction in bounces for each of these SKU.
After Kaizen
Jeffersonville Warehouse Team 1: Add mortgaged Bounce Reduction Will have Consolidation process Turrets
Before
After
causes inventory to move during print-pick window (cont.)
quantity in both ‘from’ and ‘to’ bay locations on await report to inform operators of required inventory.
fewer bounces from consolidation
Jeffersonville Warehouse Bounce Reduction Operation
Turrets
Problem
3rd Shift turret operator moves doors from levels 1-3 to empty locations. Parts moved from allocated locations.
Team 1:
Actions Taken
Results
Created new Doors Allocated Report for the 3rd shift operator.
Before Kaizen
No signal for allocated pieces
Will need to track to measure reduction in bounces for each of these SKU.
After Kaizen
Jeffersonville Warehouse Bounce Reduction
Team 1:
Target Sheet
Date:
11/13/2007
UOM
Start
Target
Picker Bounce Rate
%
3.30%
0
Door Bounces per wk
Each
165
0
Blue Bin Bounces
Each
1st Release
0
90.50%
11/30/07 2.00%
set base line
93.40%
12/7/07
12/14/07
12/21/07
Result
% Change
Jeffersonville Warehouse Bounce Reduction Kaizen Newspaper
11/15/07 11/13/07 11/13/07 11/13/07 11/13/07 11/13/07 11/13/07 11/13/07 11/13/07 11/13/07 11/13/07
11/20/07 11/16/07 11/16/07 11/16/07 11/16/07 12/8/07 11/29/07 11/16/07 11/16/07 12/15/07 12/15/07
100%
T. Bale T. Bale B. Feeler Team C. Filek C. Filek T. Elrod T. Elrod T. Elrod M. Frohme Filek / Wooldridge
75%
Have outer areas treated by exterminator Create list for identified pest areas Tool list added to Daily Checklist for operators Relabel aisles 53 - 55 Change picking SOP for blue bins Complete aisle proofing of blue bin aisles Update Results of Target Sheet Add inventory fields to Await Report Create report for door consolidation Add Allocated Qty to Move Transactions Change Pick Confirmation Process for Air Orders
% COMPLETE 50%
OWNER
TARGET COMPLETION
25%
ACTION ITEM
DATE ASSIGNED
Team 1:
X X X X X X X X X
Jeffersonville Warehouse Bounce Reduction
Team 1:
Lessons Learned
• Old and unaccounted for inventory in the warehouse. • Items in many locations. • Current inventory consolidation processes interfere with pick accuracy. • It would be valuable to have visibility to allocated inventory. • On demand allocation would be valuable. • More RF less paper. • Jay would be a valuable addition to IQ.