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: 8-29-

2008

Team Members
E

Tom Elrod
R
TU

Brandon Feeler
C
PI

Aaron Jackson
AM

Nate McWherter
TE

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)
7)
A B C

A B C

3) 4)

1 2 3 001 036 001

123-456-
789
Need 3…
8) Scan 1…
5) 6)
Scan 2…
Scan 3…
Operation Problem Actions Taken Results
- RTS labels missing needed - Redesigned labels to - Increased data to
information capture necessary facilitate continuous
Blue Bins - Difficult for packer to fill out information improvement

Before Kaizen After Kaizen

Operation Problem Actions Taken Results
- No system for recording and - Built Access DB & form to - Increased data to
tracking RTS capture and report RTS facilitate continuous
Blue Bins data improvement
- Implemented process
where team leaders record
information from RTS tags
at end of shift
Before Kaizen After Kaizen
Before

RTS tag filled

Labels turned
RTS out by packer Data logged in
into pick team End
Detected and attached Excel
leads
to end of lane

After
RTS tag filled
Labels turned Team leader
RTS out by packer
into pack team enters tag data
Detected and attached
leader into database
to end of lane

Reports
Supervisor findings to
prints summary team and
End
report prior to discusses
standup with
individuals
Operation Problem Actions Taken Results
- Messy shelves - New standard labels on - Labels easier to
- Labels missing or hard to 1057 bins read
Blue Bins read - Scrapped 985 obsolete - Faster to locate
- Obsolete SKU’s in bins SKU’s part
-Removed trash - Reduced miss-picks
by 46%

Before Kaizen After Kaizen

Operation Problem Actions Taken Results
- Pickers are not always - Added high visibility - Constant reminder
verifying part numbers in bins reminders to verify part to check part
Blue Bins numbers numbers
- Reduced miss-picks
by 46%

Before Kaizen After Kaizen

Operation Problem
- Pickers are not always
verifying the part number
Blue Bins when pulling from Blue bins
Actions Taken Results
- Created new signage - Constant reminder
and added reminder to check part
labels to pick lifts numbers
- Reduced miss-picks
by 46%

Before Kaizen After Kaizen

Operation Problem Actions Taken Results
- Pickers are not always - Created new signage - Constant reminder
verifying the part number to check part
Blue Bins when pulling from Blue bins numbers
- Reduced miss-picks
by 46%

Before Kaizen After Kaizen

Operation Problem Actions Taken Results
- Most needed items scattered -Moved most needed items -PowerBand picks
across levels into PowerBand levels 3-4 increased from 44%
Blue Bins to 61% NTO

Before Kaizen 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
% COMPLETE
ACTION DATE TARGET
OWNER

100%
ASSIGNED COMPLETION

25%

75%
50%
ITEM
Continue to increase awareness
Pasierbowicz/Feeler FW 35 FW 35 X
through visual management
Asile proof and relabel blue bins Pasierbowicz/Feeler FW 35 FW 45 X
Continue powerbanding blue bins Pasierbowicz/Feeler FW 35 FW 45 X
Created RTS tracking tool McWherter FW 35 FW 35 X
Updated QS9000 documentation Feeler FW 35 FW 35 X
Picker issue resolution log Pasiebowicz FW 35 FW 35 X
Scrap old blue bin skus Entsiminger FW 35 FW 35 X
Identifed potential facility wide
Feeler/Elrod FW 35 FW 35 X
waste
Investigate hand held label printers Pasierbowicz/Bale FW 35 FW 37 X
Facility wide review meeting with
Feeler FW 35 FW 35 X
pickers
Continue to document and train on
Pasierbowicz/Feeler FW 35 FW 36 X
new RTS tracking & diagonosis
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