Pick by Label AWO improvement

Jeffersonville Warehouse Team Jeffersonville Warehouse Team 2: Short Ship2: Short Ship

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AWO FW 46 “I empower this team to follow the guidelines of Action Workout and support all decisions that are made by the team.”

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

Team Members

Jamie Herman - GE Parts Quality Mgr

Mark Barnsfather Op Mgr TMSi

Ed Huttunen - GE Mgr Parts Management

Brian Davis – GE coop Parts Management

Eric Delgado – TMSi Packer

Mike Alain – GE Parts Planner

Cameron Cornelison – GE coop Parts Dist

Brandon Chasteen, BB

Tom Ledbetter – GE Technician


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•Mistake proof the shipment of courier tech parts.

•Eliminate warehoused caused courier tech short ships.

Goals & Objectives

AWO – Jeffersonville Nov 13-16, 2007

Short Ships as % of Shipments

$0

$1,000,000

$2,000,000

$3,000,000

$4,000,000

$5,000,000

$6,000,000

$7,000,000

$8,000,000

Jan Feb Mar Apr May Jun Jul Aug Sept

0.00%

0.50%

1.00%

1.50%

2.00%

2.50%

Total $ ShippedShortShip %

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44

Other

PD

Tech

Short Ships by Channel

Missing Shipments

# OF MISSING SHIPMENTS PER FW AT 5100

-

500.00

1,000.00

1,500.00

2,000.00

2,500.00

3,000.00

3,500.00

4,000.001 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 49 52

FW

# M

issing

Shi

pmen

ts 2006

2007

Item # Desc Total Short shippedWX8X73 FLEX-DUCT-BAGGED W 2 CLM 1584WX9X18 DRYER CORD 4' 30 AMP 4 W 1119WX08X10006 6SMRTCONECT 805

WX9X20 DRYER CORD 6' 50 AMP 4 W 748PM28X319 D/W CONN KIT 680

WX10X10200 DW MAGIC 12 OZ 612

MWF WATER FILT REF CYST 606

WR55X10552 BOARD ASM MAIN DOMESTIC 550

PM08X20073 SEMI-RIGID DUCT 480

WB02X10700 FILTER CHARCOAL 458

WR51X10053 HEATER & BRACKET ASSY 379

WR60X162 MTR EVAP FAN 323

WX9X3 DRYER CORD 5' 30 AMP 3 W 314WX08X10130 4IN TENSCLMP 300

WX9X35 RANGE CORD 4' 40 AMP 4 W 284WX15X38 1/2 MIPX3/8 FIP SS GAS C 250

WR57X10051 WATER VALVE KIT 226

WB2K20 BRKT ASM A-T 206WR50X55 THERMO PKG 202

WD26X10013 MECHANISM ASSY PS KIT 184

WR60X10141 MOTOR AC/DC 170

WB36X10003 LAMP-INCANDESCENT157

WR30X10061 ELECTRONIC IM DOMESTIC 153

WH49X10042 KIT - AGITATOR COUPLING 148

WX60X1 U COMP BG 15 146

Highest Short Ship Items 3Q 2007

Highest Short Ship Customers

CYB89 11283.698 1ST SOURCE PARTS CENTER

DLP41 10581.002 AP-WAGNER INC.

ZCJ77 8623.678 RALPH'S TRANSFER CO.INC.

19758 8538.642 TEDS TV SALES & SERVICE

CWX57 8497.718 SERVALL COMPANY

CGN92 8371.387 RELIABLE PARTS INC

WXT20 8235.188 MAINTENANCE WAREHOUSE

CRC76 8156.172 MARCONE

TLW51 6336.057 APPLIANCE PARTS DEPOT LP

ZSR17 6007 SPIRIT DELIVERY

P4X50 5925.303 MARCONE APPLIANCE PARTS

DYP38 5250.094 DEY APPL SERVICE CO INC

D9R43 5196.186 SUNDBERG CO

Highest Short Ship Techs

Tech Sept YTD Shortship Pieces Sept YTD Short Ship $MIKE KRIGBAUM 42 $8,912.50MICHAEL CLEVELAND 223 $5,520.04

BRAD MILLER 216 $4,258.81ROY AGUIRRE 281 $4,163.21JAMES RANSFORD 372 $4,035.46

GEORGE MATHIS 478 $3,986.43

GLENN SMITH 233 $3,818.86MICHAEL CLEVELAND 284 $3,594.79

MARK HALE 362 $3,534.38TRENT WOLFKILL 260 $3,428.32

PATRICK TRAVICA 134 $3,197.94MICHAEL KNOX 76 $3,095.18JAMES BRYANT 277 $3,088.66HENRY RANDALL 112 $3,077.69

T.DEAN JANUS 267 $3,068.94MICHAEL SUHU 209 $3,062.08WILLIAM SAYERS 187 $3,023.27THOMAS FERREIRA 188 $2,928.81

MARK WALSH 155 $2,915.48LEO CARAMAZANA 287 $2,871.24


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Chicago 1Chicago 2Chicago 3

ClevelandPittsburghDetroit NorthDetroit SouthKansas CityGrand RapidsCleveland

St. Louis

Eden Prairie

Dallas West

Dallas East

LouisvilleColumbusIndianapolisDaytonCincinnati

Jeffersonville Warehouse

Vitran Express

SAIA

Averitt Express

Blast Express

Relay Express

Velocity Express

Mike Rix Courier

CD&L/1st Choice Courier

Orbit Courier

Jeffersonville to Carrier to Courier to

Zone


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Idea Generation Sheet – 7 Ways

•Pick by courier route

•RF Pick

•Finger scan & Label Printer – label include: part number, part loc, order number, tech, route, date/time

•Pick by label in pick sequence

•Blow up courier routes and ship direct to tech

•Pick by location and then sort

•Pick into bullpen instead of pallet

•Label bullpen locs on floor and document with a map

•Color code routes

•Sort pallets as completed. Do not accumulate pallets and sort at end of day

•Stagger route shipment days


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Before Kaizen After Kaizen

Operation Problem Actions Taken Results

Parts are collected on pallets and carried to the sorting area. Opportunity for part to be picked, and counted as picked but fall off the skid and never be noticed. Result is a short ship

Pick for courier tech orders

Utilize the cardboard bullpens to collect parts prior to sorting. Could also use returnable containers with drop sides.

Parts do not fall from pallet while traveling or sorting.


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Parts are collected into a central area and then the pickers sort into the bullpens for each route. The location for the bullpens is totally random and changes daily. Introduces ineffeciencies in looking for the correct bullpen

Sort for courier tech orders

Developed a map with a layout for the route bullpens to be in a consistent location each day. Currently have a paper map and labels attached to the floor. Step 2 would be to make an overhead label system

More efficient sorting

Bullpens were randomly located with day to day variation


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Eden Prairie (Orbit)

Saint Louis (CD&L)

Cleveland (DL)

Kansas City (Vitran)

Dallas East (Blast Exp)

(Green)

Courier Tech Layout and Schedule

Louisville (RX)

Cincinnati (RX)

Pittsburgh (DL)

Dayton (RX)

Tab

le

Chicago 1 (CH) (Red)

Detroit South (SO) (Gray)

Chicago 3 (CH) (Purple)

Grand Rapids (SO)

Indianapolis (RX)

Chicago 2 (CH)

(Mustard)

Detroit North (SO) (Pink)

Columbus (RX)

Dallas West (Blast Exp)

(Blue)

Courier Shipping Schedule

Monday All

Tuesday Chicago and Dallas

Wednesday All

Thursday Kansas City and Dallas

Friday All; except Kansas City and Dallas


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Parts are collected into a central area and then the pickers sort into the bullpens for each route. There is opportunity to sort into the wrong bullpen which would result in 2 defects. A part sent that was not ordered and a part shorted from where it should have shipped

Pick and sort courier tech orders

Each picker picks by courier route eliminating the need to sort.

Eliminate sorting so that 2 more hours a day can be spent picking


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Pickers manually sort their pick sequence from several orders. No validation that all orders have been picked complete and additional opportunity for shipping to wrong location during sorting.

Pick by a route that is sorted into pick sequence using labels for parts

Print labels by courier route in pick sequence. Unused labels are taken to team lead to bounce or alternate pick location. No need for sorting.

Eliminate sorting so that 2 more hours a day can be spent picking. Eliminate ship from not being picked.

Loc: 002-23-005 Pcs: 1Part: WR52X10052Desc: thingamabobOrder: 5431234Tech: T123 Route: LOUItems on order 3 Last item on order N


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Tech and courier route information is handwritten on the part. The location of the writing, abbreviations is not consistent. Writing may not be legible.

Recording of tech and courier route information on partle

Print labels by courier route in pick sequence. Labels are placed on the part identification side of the box.

Documented in SP400015.

Labels are legible, contain more information that handwritten tech and courier information and consistent location on part



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Documentation for Labels SP400015•TECH COURIER ORDERS MUST BE LABELED WITH MINIMUM OF TECH NUMBER AND COURIER ROUTE

•EACH PART MUST BE LABELED

•THE LABEL SHALL CONTAIN THE FOLLOWING

•· PART LOCATION

•· PART NUMBER

• PART QUANTITY

• PART DESCRIPTION

•· ORDER NUMBER

•· TECH NUMBER

•· COURIER ROUTE

• ITEMS ON ORDER

• LAST ITEM ON ORDER (YES OR NO)

• BARCODE INFORMATION


Bar code


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The parts contain tech and route information that is not being removed or covered which leads to shipping errors

Receipt of tech parts that are RTS

Develop SOP with work station instruction to cover all tech numbers and route information with paper tape before RTS

Documented in SP200003

Eliminates previous tech information so that only the correct tech information is visible

Paper tape covering tech

information but not the part number


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Check MID’s for correct quantity, backorder quantity and storage location.

Cover and/or remove any shipping labels or markings on box.

Cover small holes and blemishes with paper tape

Make sure your MID doesn’t have a Backorder Qty greater than 0 on the MID paper

If the MID has a Backorder Qty greater than 0, circle it with a red marker.

Locate the Storage Location on the MID

Attatch the MID to the part you just returned

If the MID had a backorder place the part in a backorder skid or tote

If no backorder then place the part in the appropriate skid or tote for location

Documentation for Tech Returns SP200003


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Courier routes, addresses and information had not bee updated from the last time the couriers changed

Tech Courier Route Shipping Prep

Corrected the bullpen courier label information. Saved documentation and updated pickers supply.

Include this process in the SOP for courier route changes.

Eliminate possible shipping error due to wrong courier information or incorrect addresses

Cincinnati

SAIA

498 Commercial Dr.

Fairfield, OH 45014

ATTN: Relay Express

Ph: (513) 860-2555

Wrong information


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Ship confirmation of courier tech orders are done throughout the day without regard to whether or not he order has been picked or will actually ship today. If there is a bounce from the order, there is no opportunity to correct the order as it has already been ship confirmed. Order will show as shipped even if not due to ship

Ship confirmation of courier tech orders

Ship confirmation transactions to only be completed AFTER order has been picked and confirmed thqt all items were shipped.

Documented in SP300010

Eliminate short ships as a result of bounces that were not documented on order

No documentation regarding when to ship confirm

After KaizenBefore Kaizen

TECH CONFIRMATION

TO BE COMPLETED AFTER ORDERS HAVE BEEN PICKED

Enter WH108 at main menu

Press Enter

Enter the User ID of the person who printed the WAVE

Press Enter

Place a “1” by all of the tech courier orders that were printed for that day

Press Enter

Print screen


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Target Sheet

Date: 11/13/2007

UOM Start Target 1st Day 2nd Day 3rd Day 4th Day Result % ChangeCourier Tech Short Ships $

$12904 ytd avg 0

Standard Work for Sorting Yes/No No Yes 10% 25% 75% 100%Productivity lines per hour Route defect 12 0 12 6 0 0

Order defects 0 7.59% 0 0

Validate in 4-6 weeks


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Kaizen Newspaper

25%

50%

75%

100%

Map bullpen locations Bryan Davis 11/13/07 11/13/07 XTemporary label bull pen locations Bryan Davis 11/13/07 11/13/07 XPermanent label bull pen locations Bryan Davis 11/13/07 11/16/07 V

Pick number on pick sheet Mark Barnsfather 11/13/07 11/14/07 XTech number and route on part label side Mark Barnsfather 11/13/07 11/14/07 X

Packing slip in sleeve in readible orientation Mark Barnsfather 11/13/07 11/14/07 XCover old tech info on RTS Ed Huttunen 11/13/07 11/14/07 XPoles for bull pen locations 11/13/07 11/16/07 X

Correction of tech numbers, routes and freight code - standardize

Cameron Cornelison

11/14/07 11/26/07 X

Simulate pick by route Jamie Herman 11/13/07 11/16/07 XSimulate pick by label Jamie Herman 11/13/07 11/16/07 X

Establish SOP for returns Ed Huttunen 11/13/07 11/16/07 XEstablish SOP for courier route changes Cameron

Cornelison11/14/07 11/16/07 X

Update carrier information on bullpen labels Cameron Cornelison

11/14/07 11/15/07 X

SOP for courier tech bounce Jamie Herman 11/14/07 11/15/07 XVisual aid for tech returns Eric Delgado 11/13/07 11/15/07 X

Label spec Ed Huttunen 11/13/07 11/15/07 XMITR for label spec and process Ed Huttunen 11/13/07 11/20/07 X

Implement label pick Ed Huttunen/ Jamie Herman

11/13/07 TBD

Eliminate bags for small part courier tech orders

Jamie Herman 11/13/07 12/1/07 X

% ACTION ITEM OWNER DATE ASSIGNED

TARGET COMPLETION


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•Sorting process is an opportunity to have a shipping error

•Parts can fall from pallet of picker and cause a shipping error

•Haz/mat materials follow different shipping process

•Importance of current SOP and following the SOP

•Handwriting tech number and route on boxes can vary.

•RTS from techs must have tech and route number removed or it can cause a shipping error

•Orders can be confirmed before they are complete which can lead to a shipping error

•We do not have an audit process for tech courier orders

•Route on address header is different from the route on the instructions

•Courier route changes were not reflected in the bullpen shipping labels

•Why why why why why

Lessons Learned


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The Team at Work

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