Process Improvement Ideas Abe Taleb José G. Rodríguez

Kaizen Events Small process improvements that can be set up and executed in a short period of time. Usually accomplished at little or no expense, without sophisticated techniques or expensive equipments. Focus on simplification by breaking down complex processes into their sub-processes and then improving them.

Customer Needs Customer Need #ImportanceNeedComments CN15 Increase order and location accuracyRedesigning labeling ADM CN23 Increase worker utilizationDesign alternative picking methods CN33 Install visual aids to prevent errors Reduce number of boxes that go to ADM CN45Reduce waste Reduce number of boxes that are not diverted in shipping Rating scale Very important5 Moderately important3 Less important1 Not approved0

Specifications Customer Need #SpecificationsMetric CN1Increase order and location accuracy by 10% Order / location accuracy CN2Increase worker utilization by 15% Individual worker utilization CN3Reduce by 50% boxes that get to ADM Number of boxes that go to ADM CN4 Reduce by 15% the number of boxes not diverted Number of boxes that go to ADM

Categories: Ease of implementation Cost benefit ratio Time to implement Customer priority Weights were assigned to each of the categories. Based on these weights, 10 were pre-selected. After customer discussions, this selection process concluded with 5 improvement opportunities. Selection of Improvement Ideas

Rating Rating Scale MetricWeight531 Ease of implementation0.20Easy to implement Moderately difficult to implement Difficult to implement Cost/benefit ratio0.20Low ratioMedium ratioHigh ratio Time to implement0.10<6 hrs<12>24 hrs Customer Priority0.50Very important Moderately important Less important Due to time constraints, the team will only be able to execute at most three out of these five.

Reduce the # of boxes that go from Pack to ADM Shipping Boxes reach the ADM with certain frequency. This must be reduced in order to minimize the number of late shipments. reduce waste associated with personnel having to take these boxes back to shipping.

Reduce the # of boxes that go from Pack to ADM Visual aids specifying which conveyor is for totes and which one is for boxes, could potentially reduce this. This will increase accuracy, serving as an aid in the decision making process. Cost: <$100 Time to implement : <6 hrs

Reduce the # of boxes that go from Pack to ADM

Order accuracy and inventory accuracy are metrics in yellow. ADM has the lowest inventory and order accuracy (<81%). It is assumed that the number of errors in replenishment due to poor label design is large. Redesign Labeling of Slots in ADM

In the ADM, these metrics can be increased by redesigning the labeling of the slot locations. Cost: <$500 Time to implement: <12 hrs Redesign Labeling of Slots in ADM

Redesign Labeling of Slots in ADM

Currently when orders are slow pickers login and logout from each section with a single tote. Process is very wasteful. If a worker logs in picks one or two totes, checks induct, then logs back out again this triples picking time. Workers could be used in other areas. Design new method to reduce idle time in PTL

Let a small queue be generated at each PTL divert when orders are slow. More of a mentality switch then anything else. Cost: Minimal Time to implement: <1 week

Fix Shipping Conveyor Boxes to be shipped either are turned over or are to far to a side of the conveyor to be read by the Quantum Sorter. Turned over boxes are either placed on conveyor upside down or flipped during transit. Results in boxes to be sorted by hand. Reaching into bins creates poor ergonomic conditions.

Fix Shipping Conveyor Smaller bins for boxes that can not be read. Visual reminders to place box on conveyor tracking number side up. Mechanical solution to prevent boxes from being flipped over in transit. Will increase productivity of workers. Cost: $20 - $500 Time to implement: <24 Hrs

Dedicated Time for Bulk Picking Workers bulk picking often prevent other workers from picking. No apparent benefit from picking bulk during the day. 48 hour time goal for bulk would allow for picking to be delayed. One idea is to only pick bulk in the morning when orders are slow.

Dedicated Time for Bulk Picking Another idea is to pick bulk from 3am to 6am when there is very little going on in facility. Would only require rescheduling of a small handful of workers. Productivity would increase across the board. Cost: Minimal Time to implement: <1 week