Jeffersonville Warehouse Team 1: Bounce Reduction

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“I empower this team to follow the guidelines of Action Workout and support all
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decisions that are made by the team.”

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Robert Wooldridge, Warehouse Mgr. Date: 11-13-2007

Team Members
E
R

Tom Elrod Transportation

TU

Chad Filek IQ manager

C

Terry Bale Operations

PI

Tim Wyatt Turret Team Leader

AM

Rita Moses IQ
TE

Jay Shepherd Pick associate

Tom Ording Black Belt
Mike Frohme King of IT
Jeffersonville Warehouse Team 1: Bounce Reduction

Goals & Objectives

• Eliminate bounces in the bulk area Aisle 70

• Eliminate bounces in the door area Aisles 53-

56
Jeffersonville Warehouse Team 1: Bounce Reduction

Bounce Rate by Week and Type

7.0%
6.0%
5.0%
4.0%
3.0%
2.0%
1.0%
Total Bounce Picker Bounce WH Bounce
0.0%
200730

200732

200733

200734

200735

200737

200738

200740

200742
200731

200736

200739

200741
Jeffersonville Warehouse Team 1: Bounce Reduction

Pareto of Bounce by Item Type

8.0%
7.0%
6.0%
5.0%
4.0%
3.0%
2.0%
1.0%
0.0%
WR78

WR02
WH45
WB31
WB27

WR17
WB56
WR24
WH12
WR60
WR32
WB36
WB07
WH20
WR55
WR12
WB62
WR71
WD21
WD12
Jeffersonville Warehouse Team 1: Bounce Reduction
Jeffersonville Warehouse Team 1: Bounce Reduction

40
35
30
25 Count
20
15
10
5
0

* Non-measurable occurrences
Jeffersonville Warehouse Team 1: Bounce Reduction
Pugh Concept Selection Matrix
Concepts
Note: Pick one concept as the "Datum" or Baseline Concept

Locations by SKU

Allow Directed Pick

Inventory Process
Single Pickable

Allocated order
Replenishment
Pick All Orders

WMS Directed

(multiple locs)

Consolidation
Remortgate
Same Day

visability
Improved
Criteria Rating
Safety
Operator Safety 5 S S S S S S S
Traffic 3 S - + S + S S
Sprains/Strains 4 S S S S S S S
Quality
Number of handles 3
Pick accuracy / order accuracy 4 + S + S - + +
FIFO 1 S S S S S S S
Inventory accuracy 4 S S + + - + +
Bounce rate 5 S - + S + - S

Delivery
Pick cycle time 4 + S S S S S S
Pack cycle time 4 S S S S S S S

Cost
Lines per hour 4 S + + + - + S
Implementation cost 4 - S - S - + +
Implementation time 3 + - - S + + +
Transportation 4 S - + S + - S
Sum of Positives 3 1 6 2 4 5 4
Sum of Negatives 1 4 2 0 4 2 0
Sum of Sames 9 8 5 11 5 6 9
Weighted Sum of Positives 11 4 24 8 15 19 15
Weighted Sum of Negatives 4 15 7 0 16 9 0
7 -11 17 8 -1 10 15
Jeffersonville Warehouse Team 1: Bounce Reduction
Operation Problem Actions Taken Results

Picking Outer wall bays contain a lot Exterminator called to clear Pickers will not be
of bugs and spiders, making bins. List of effected bays reserved about reaching
picking a challenge created in Pick Central for into locations
future identification

Before Kaizen After Kaizen

Jeffersonville Warehouse Team 1: Bounce Reduction
Operation Problem Actions Taken Results

Picking Proper tools to break down Tool list added to Daily More likely to be
overpack situations not Checklist for operators. able to pick banded
standard on picker trucks. or shrink wrapped
items.

Before Kaizen After Kaizen

Driver's compartment Driver's compartment

Seat Belt\Harness attachment Seat Belt\Harness attachment
Windshield - clean Windshield - clean
Horn Horn
Lift Control - raise to check Lift Control - raise to check
Side Shift Control Side Shift Control
Tilt Control
Tilt Control
Box Cutter
Clipboard
Tape Gun
Jeffersonville Warehouse Team 1: Bounce Reduction
Operation Problem Actions Taken Results

Picking Locations on bin labels in Redesigned and relabeled Locations much

aisles 53 – 55 are covered by over 1,200 door locations easier to read,
shelving wire mesh. including check digit. which should result
in fewer bounces.

Before Kaizen After Kaizen

Jeffersonville Warehouse Team 1: Bounce Reduction
Operation Problem Actions Taken Results

Picking Inventory stock outs in blue Flip all empty blue bins after Better organization
bin area are not visually pulling final part. Added the leads to fewer
identified. instruction to SOP. bounces.

Before Kaizen After Kaizen

Jeffersonville Warehouse Team 1: Bounce Reduction
Operation Problem Actions Taken Results

Picking Inventory in blue bin area Ran test aisle-proofing to Improved inventory
inaccurate. validate error rate and accuracy in aisle-
identify most common proofed blue bin
causes. 27% error rate. locations.

Before Kaizen After Kaizen

 Non-inventoried parts

Bin of non-inventoried parts

Empty misplaced bin

Missing parts bin

Jeffersonville Warehouse

No label on bin

Mislabeled bin

Parts on floor
Failure mode in blue box area

Missing location label

Mislabeled parts

Parts in brown box

Team 1: Bounce Reduction
Jeffersonville Warehouse Team 1: Bounce Reduction
Operation Problem Actions Taken Results

Picking Consolidation process causes Consolidated doors (high Will need to track to
inventory to move during bounce category) into single, measure reduction in
print-pick window. expanded bay locations. bounces for each of
these SKU.

Before Kaizen After Kaizen

Jeffersonville Warehouse Team 1: Bounce Reduction
Add mortgaged quantity in Will have fewer
Consolidation process causes
both ‘from’ and ‘to’ bay bounces from
Turrets inventory to move during
locations on await report to consolidation
print-pick window (cont.)
inform operators of required
inventory.

Before

After
Jeffersonville Warehouse Team 1: Bounce Reduction
Operation Problem Actions Taken Results

Turrets 3rd Shift turret operator moves Created new Doors Will need to track to
doors from levels 1-3 to empty Allocated Report for the 3rd measure reduction in
locations. Parts moved from shift operator. bounces for each of
allocated locations. these SKU.

Before Kaizen After Kaizen

No signal for allocated pieces

Jeffersonville Warehouse Team 1: Bounce Reduction
Target Sheet

Date: 11/13/2007

UOM Start Target 11/30/07 12/7/07 12/14/07 12/21/07 Result % Change

Picker Bounce Rate % 3.30% 0 2.00%
Door Bounces per wk Each 165 0
Blue Bin Bounces Each 0 set base line

1st Release 90.50% 93.40%

Jeffersonville Warehouse Team 1: Bounce Reduction
Kaizen Newspaper
% COMPLETE
ACTION ITEM
DATE TARGET
OWNER

100%
ASSIGNED COMPLETION

25%

50%

75%
Have outer areas treated by exterminator T. Bale 11/15/07 11/20/07 X
Create list for identified pest areas T. Bale 11/13/07 11/16/07 X
Tool list added to Daily Checklist for operators B. Feeler 11/13/07 11/16/07 X
Relabel aisles 53 - 55 Team 11/13/07 11/16/07 X
Change picking SOP for blue bins C. Filek 11/13/07 11/16/07 X
Complete aisle proofing of blue bin aisles C. Filek 11/13/07 12/8/07 X
Update Results of Target Sheet T. Elrod 11/13/07 11/29/07
Add inventory fields to Await Report T. Elrod 11/13/07 11/16/07 X
Create report for door consolidation T. Elrod 11/13/07 11/16/07 X
Add Allocated Qty to Move Transactions M. Frohme 11/13/07 12/15/07 X
Change Pick Confirmation Process for Air Orders Filek / Wooldridge 11/13/07 12/15/07
Jeffersonville Warehouse Team 1: Bounce Reduction
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.