Rts Team
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AWO FW 35 “I empower this team to follow the guidelines of Action Workout and support all decisions that are made by the team.” Robert “Fast Draw” Wooldridge,
DC Manger TMSi
Date: 8-292008
TE AM
PI C
TU
R E
Team Members
Tom Elrod Brandon Feeler Aaron Jackson Nate McWherter Jim Pasierbowicz Terry Bale Dennis Entsminger
Goals & Objectives •Reduce overall Return to Stock (RTS) generated from the pack lines to decrease labor hours associated with miss-picks and put-a-way. • Organization and standardization on blue bin generation, put-a-way and replenishment for inventory/system accuracy
7 Ways 1)
2) A
B
C
A
B
C
3) 1
7)
4) 2
3
001
036
123-456789
5)
6)
001
Need 3… 8) Scan 1… Scan
2…
Scan
3…
Operation
Problem
- RTS labels missing needed information Blue Bins - Difficult for packer to fill out
Before Kaizen
Actions Taken
- Redesigned labels to capture necessary information
Results
- Increased data to facilitate continuous improvement
After Kaizen
Operation
Blue Bins
Problem
- No system for recording and tracking RTS
Before Kaizen
Actions Taken
Results
- Built Access DB & form to capture and report RTS data - Implemented process where team leaders record information from RTS tags at end of shift
- Increased data to facilitate continuous improvement
After Kaizen
Before
RTS Detected
RTS tag filled out by packer and attached to end of lane
Labels turned into pick team leads
Data logged in Excel
Labels turned into pack team leader
Team leader enters tag data into database
After RTS Detected
RTS tag filled out by packer and attached to end of lane Supervisor prints summary report prior to standup
Reports findings to team and discusses with individuals
End
End
Operation
Problem
Blue Bins
- Messy shelves - Labels missing or hard to read - Obsolete SKU’s in bins
Before Kaizen
Actions Taken
Results
- New standard labels on 1057 bins - Scrapped 985 obsolete SKU’s -Removed trash
- Labels easier to read - Faster to locate part - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Pickers are not always verifying part numbers in bins
Before Kaizen
Actions Taken
Results
- Added high visibility reminders to verify part numbers
- Constant reminder to check part numbers - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Pickers are not always verifying the part number when pulling from Blue bins
Before Kaizen
Actions Taken
Results
- Created new signage and added reminder labels to pick lifts
- Constant reminder to check part numbers - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Pickers are not always verifying the part number when pulling from Blue bins
Before Kaizen
Actions Taken
Results
- Created new signage
- Constant reminder to check part numbers - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Most needed items scattered across levels
Before Kaizen
Actions Taken
Results
-Moved most needed items into PowerBand levels 3-4
-PowerBand picks increased from 44% to 61% NTO
After Kaizen
Target Sheet Date:8/29/08 Team Name:
RTS
UOM Start Target 1st Day 2nd Day 3rd Day 4th Day Result % Change Aisle proofing (14) bins 0 980 300 900 980 980 980 100% High Bin NTO resolution NTO 12,310 17,179 12,310 12,579 17,179 17,179 17,179 40% RTS Lines per day 43 30 37 33 32 29 29 33% RTS (Wrong part picked) Lines of mis-picks/day39 20 28 16 19 21 21 46%
Kaizen Newspaper Continue to increase awareness through visual management Asile proof and relabel blue bins Continue powerbanding blue bins Created RTS tracking tool Updated QS9000 documentation Picker issue resolution log Scrap old blue bin skus Identifed potential facility wide waste Investigate hand held label printers Facility wide review meeting with pickers Continue to document and train on new RTS tracking & diagonosis
FW 35
FW 35
X
Pasierbowicz/Feeler Pasierbowicz/Feeler McWherter Feeler Pasiebowicz Entsiminger
FW FW FW FW FW FW
FW FW FW FW FW FW
X X
35 35 35 35 35 35
45 45 35 35 35 35
Feeler/Elrod
FW 35
FW 35
Pasierbowicz/Bale
FW 35
FW 37
Feeler
FW 35
FW 35
Pasierbowicz/Feeler
FW 35
FW 36
100%
Pasierbowicz/Feeler
75%
OWNER
TARGET COMPLETION
50%
% COMPLETE DATE ASSIGNED
25%
ACTION ITEM
X X X X X X X X
Lessons Learned •
Always involve the process experts
•
Data is important
•
Walking the floor is the best way to observe the process
•
A concentrated team effort can lead to extraordinary results
•
Continuous improvement is important to reach your goals
•
Lunch is a great way to bring team members together
DC Manger TMSi
Date: 8-292008
TE AM
PI C
TU
R E
Team Members
Tom Elrod Brandon Feeler Aaron Jackson Nate McWherter Jim Pasierbowicz Terry Bale Dennis Entsminger
Goals & Objectives •Reduce overall Return to Stock (RTS) generated from the pack lines to decrease labor hours associated with miss-picks and put-a-way. • Organization and standardization on blue bin generation, put-a-way and replenishment for inventory/system accuracy
7 Ways 1)
2) A
B
C
A
B
C
3) 1
7)
4) 2
3
001
036
123-456789
5)
6)
001
Need 3… 8) Scan 1… Scan
2…
Scan
3…
Operation
Problem
- RTS labels missing needed information Blue Bins - Difficult for packer to fill out
Before Kaizen
Actions Taken
- Redesigned labels to capture necessary information
Results
- Increased data to facilitate continuous improvement
After Kaizen
Operation
Blue Bins
Problem
- No system for recording and tracking RTS
Before Kaizen
Actions Taken
Results
- Built Access DB & form to capture and report RTS data - Implemented process where team leaders record information from RTS tags at end of shift
- Increased data to facilitate continuous improvement
After Kaizen
Before
RTS Detected
RTS tag filled out by packer and attached to end of lane
Labels turned into pick team leads
Data logged in Excel
Labels turned into pack team leader
Team leader enters tag data into database
After RTS Detected
RTS tag filled out by packer and attached to end of lane Supervisor prints summary report prior to standup
Reports findings to team and discusses with individuals
End
End
Operation
Problem
Blue Bins
- Messy shelves - Labels missing or hard to read - Obsolete SKU’s in bins
Before Kaizen
Actions Taken
Results
- New standard labels on 1057 bins - Scrapped 985 obsolete SKU’s -Removed trash
- Labels easier to read - Faster to locate part - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Pickers are not always verifying part numbers in bins
Before Kaizen
Actions Taken
Results
- Added high visibility reminders to verify part numbers
- Constant reminder to check part numbers - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Pickers are not always verifying the part number when pulling from Blue bins
Before Kaizen
Actions Taken
Results
- Created new signage and added reminder labels to pick lifts
- Constant reminder to check part numbers - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Pickers are not always verifying the part number when pulling from Blue bins
Before Kaizen
Actions Taken
Results
- Created new signage
- Constant reminder to check part numbers - Reduced miss-picks by 46%
After Kaizen
Operation
Blue Bins
Problem
- Most needed items scattered across levels
Before Kaizen
Actions Taken
Results
-Moved most needed items into PowerBand levels 3-4
-PowerBand picks increased from 44% to 61% NTO
After Kaizen
Target Sheet Date:8/29/08 Team Name:
RTS
UOM Start Target 1st Day 2nd Day 3rd Day 4th Day Result % Change Aisle proofing (14) bins 0 980 300 900 980 980 980 100% High Bin NTO resolution NTO 12,310 17,179 12,310 12,579 17,179 17,179 17,179 40% RTS Lines per day 43 30 37 33 32 29 29 33% RTS (Wrong part picked) Lines of mis-picks/day39 20 28 16 19 21 21 46%
Kaizen Newspaper Continue to increase awareness through visual management Asile proof and relabel blue bins Continue powerbanding blue bins Created RTS tracking tool Updated QS9000 documentation Picker issue resolution log Scrap old blue bin skus Identifed potential facility wide waste Investigate hand held label printers Facility wide review meeting with pickers Continue to document and train on new RTS tracking & diagonosis
FW 35
FW 35
X
Pasierbowicz/Feeler Pasierbowicz/Feeler McWherter Feeler Pasiebowicz Entsiminger
FW FW FW FW FW FW
FW FW FW FW FW FW
X X
35 35 35 35 35 35
45 45 35 35 35 35
Feeler/Elrod
FW 35
FW 35
Pasierbowicz/Bale
FW 35
FW 37
Feeler
FW 35
FW 35
Pasierbowicz/Feeler
FW 35
FW 36
100%
Pasierbowicz/Feeler
75%
OWNER
TARGET COMPLETION
50%
% COMPLETE DATE ASSIGNED
25%
ACTION ITEM
X X X X X X X X
Lessons Learned •
Always involve the process experts
•
Data is important
•
Walking the floor is the best way to observe the process
•
A concentrated team effort can lead to extraordinary results
•
Continuous improvement is important to reach your goals
•
Lunch is a great way to bring team members together
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