Picking – Productivity - A location Kaizen 16
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The document describes a proposed solution to improve productivity in the outbound picking department. It involves splitting picking and packing tasks between two teams rather than having one team do both. Key steps include defining the problem, measuring current performance, analyzing causes, improving processes, and controlling future performance. Initial results from testing the new approach showed productivity increased by 20% to an average of 185 lines per shift while claims were reduced by 70%.
Picking – Productivity - A location Kaizen 16
- 1. Problem : Productivity Department : Outbound – Picking Area identified for trailing : 4 tire area – A Zone Suggestion : Want to solve the problem by using method of - DMAIC - PDCA
- 2. STEPS DEFINE Identified the problem – Productivity. Unable to get productivity target (Outbound Sales) – 200 Line with in 8 Hrs. Achieving Average 145 with in 8 Hrs. MESSURE Identify the gap between current and required performance. Gap to be achieved – min 25% more than existing . Collected existing Daily productivity report ANALYSE Listed out prioritize potential causes of the problem. Usually sales team will have 3 members. Now we want picker to be merged with Binning Team. Picker will do only picking. IMPROVE Created simplest and easiest plan. Test solutions using Plan-Do-Check-Act (PDCA) cycle method. CONTROL Formatted new format for future to sustain the improvement efficiency. DMAIC – STEPS
- 3. PLAN Identified the problem WHAT WHO WHERE Productivity As a tem Sales For trail purpose identified A zone and team Collected data on zone ,Layout pick type material size and team members & training Information on implementation shared with respective team and explained the purpose. DO Segregated data's – On valid point wise. Made a new process and framed new format New Process 1.Team has to be split. 2.Timing of picking and packing has to be registered. Given training on new implementation to respective team. Explained the team with data where we have failed and due to why. Started trailing CHECK Measurement on trailing registered. Picker started to work independently. Picking start time and end time register happening. Monitored on performance and validate training effectiveness. Monitored on Data entry on new format. Collected data and suggestion on trailing from picker team. Analyzing the data registered against on trail. ACT Reviewed feedback. Planned to start 2nd phase trail.
- 4. Old Format Date Line Challan Qty Val New Format Date Line Challan Qty Val Start Time Close Time Diff
- 5. Picking – Productivity Team capacity – 03 Team with (Outbound) – 03 Team – 02 Packer - 1 Helper - 1 Picker - 1 Present practice Suggested Packer & Helper Picker will be merged with Binning Team (Inbound) Target – 200 Lines – 8 Hrs Achieving – 140 Lines (Avg) – 8 Hrs
- 6. Current status Timing Not Maintaining Manpower 3 Productivity Achieving less than 80% Claim Unable to monitor & Control Accuracy – Location Inventory Unable to control Draw back: In current practice
- 7. Current practice Suggested Productivity Not Maintaining Going to Maintain Manpower 3 2+ 1 Claim Rare Controlling Can control 95% Location Accuracy Unable to Control Can control 95% Inventory Accuracy Unable to Control Can control 95% Productivity Giving 85% to 90% Can achieve more than 100% Rare case only will come down to 80% 90% due to huge Qty Benefits : After change
- 8. Old Practice (3 person a team) – Team performance report Date Line Chl Qty Val 16.04.2014 152 32 1678 7.17 21.04.2014 150 24 1456 8.89 22.04.2014 112 16 1555 5.63 23.04.2014 115 17 598 3.86 24.04.2014 170 25 1136 10.76 25.04.2014 184 27 1369 7.03 26.04.2014 171 41 1543 13.04 30.04.2014 169 39 1900 13.2 Total 1223 221 11235 69.58 Date Line Chl Qty Val 15.04.2014 50 10 973 4.56 16.04.2014 144 23 1877 13.31 18.04.2014 167 31 1994 10.69 21.04.2014 162 21 1818 11.92 30.04.2014 104 21 698 3.78 Total 627 106 7360 44.26 AVG : 156 AVG : 125 Packer Name : Mr. Manju Packer Name : Mr. Harish
- 9. Date CH Line Qty Value Time taken Tkt Diff 5/5 16 197 1426 876409.02 6:27 200 3 5/6 26 218 1853 1000759.03 4:36 200 -18 5/7 23 211 1248 640487.61 4:51 200 -11 5/8 22 161 2592 925217.71 5:39 200 39 5/9 12 131 2087 1606866.34 5:10 200 69 5/10 28 134 2041 1323214.1 6:42 200 66 5/12 23 156 3366 1042307.81 5:35 200 44 5/13 34 209 1764 926398.53 4:31 200 -9 5/14 34 203 1695 1192973.18 4:58 200 -3 Date CH Line Qty Value Time taken Tkt Diff 5/5 19 189 1113 515109.81 4:09 200 11 5/6 29 180 1488 758204.29 4:32 200 20 5/7 26 197 1078 786213.86 3:19 200 3 5/8 26 172 3809 1215997.17 6:42 200 28 5/9 13 167 1845 883376.79 5:40 200 33 5/10 22 114 693 528700.31 3:19 200 86 5/12 29 204 1147 616593.24 6:40 200 -4 5/13 31 202 1271 844067.25 5:37 200 -2 5/14 38 234 2728 1157857.23 6:38 200 -34 Date CHLine Qty Value Time taken Tkt Diff 5/6 31 193 1144 680389.26 5:07 200 7 5/7 31 203 1008 682592.44 4:13 200 -3 5/8 23 160 3465 1400349.79 5:23 200 40 5/10 27 207 1094 688901.07 5:25 200 -7 5/12 34 189 1473 894294.49 4:40 200 11 5/13 30 204 1595 1011110.76 5:40 200 -4 5/14 31 215 2049 1418591.98 6:33 200 -15 5/15 33 245 1973 987764.24 6:57 250 5 AVG : 184 AVG : 180 AVG : 196 Picker Name : Mr. Chandrasekar Trail proof
- 10. Result : Based on analyses average picking time for one manpower is 5.5Hrs. In this 5.5 Hrs Average productivity line is 185. Claim has been reduced by 70% due to this implementation. S. No Improvement Old New % 1 Productivity 145 185 20 2 Claim 10 3 70