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Project Data
Client: Fortune 500 Global Corporation specializing in Robotics, Power, Electrical Equipment & Automation Technology
Location: Northern Mississippi, USA
Timeframe: One Months
Key Project Factors: People, process and system challenges had developed throughout the facility due to lack of KPI and departmental expectations; impacting labor performance and utilization throughout the distribution operations. Without studying the activities at the elemental level, constructing multi-variable engineered standards and identifying continuous improvement opportunities, the client would have been unable to address the inefficient process and facility layout challenges negatively impacting their throughput and performance.
The Challenge
Client struggled to move outbound product from the picking area to the shipping dock. Unnecessary work steps throughout the picking to shipping process created extra handling and delays that hindered product from being shipped in a timely manner. Inefficient timing and flow of the outbound processes working together also created the need for staging space before being shipped, creating dock congestion and extraneous process work steps. Facility layout constraints drove more delays and confusion as a result of not enough storage areas.
The Approach
CONTINUUM redesigned work steps to remove non-value added movement of product from picking to various staging areas before being put on an outbound trailer. Combined and redefined job functions between picking and shipping operations allowing product to go directly from the picking functions, consolidated at the shipping lanes, and delivered straight to the pallet wrapper. This in turn eliminated the need for temporary storage and allowed pickers to consolidate and prepare the outbound pallet themselves.
The Results
By eliminating 100% of the staging areas, removing work steps, and redefining department roles, processing times from picking to shipping decreased; ultimately increasing area efficiency by 25%. As a result of increased efficiency in non-con pallet jack picking, overall outbound productivity was also positively impacted.
