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Neil Thomas
Neil Thomas

The document outlines a Kaizen event held in November 2011 to improve the shipping process at a company. It describes preparing for the event by establishing needs, metrics, and getting team input. The event involved mapping the current process, identifying issues over 5 days, creating a future state map, implementing changes, standardizing the new process, and reporting results. Key issues with the current process included quality errors, long pull times, and low productivity. The ideal future state was described as on-demand just-in-time flow that is simple, direct, defect-free, and low cost.

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Shipping: Process to Pull MRLs & Requisitions November 2011 Kaizen Event
Preparation Work: Establish the Need (Business case). Performance Metrics. Demand Value Statement, Key Reqmts, Collect Team Member Ideas Outline of the Week
Day 1 : Grasp the Current State Map the current state Spaghetti Diagrams Map the Information & Material Flow Study each process step. Process cycle times, WIP, total flow time, etc Statement of the Ideal Create Future State Day 2: Big Changes (make the change) Day 3: Run the new process Day 4: Standardize & Train Stabilize new process Day 5: Report results. Outline of the Week
Business Case Growth is expected: From $120 M to $200 M approx 15-20% / year Market Pressures Drive: Complexity Speed Quality Pricing Create a process capable of making: perfect shipments, more often, with less effort. Shipments 2010 2011 2012 Parts Shipped / month 210,000 220,000 235,000
Value Statement What Value does the Shipping Team bring to HF and The customers? Product Knowledge JIT Delivery in Perfect Condition With product knowledegable personnel we will deliver to our customer the products when wanted, where wanted, and in perfect condition.
Stand Up Rack V S M
Requisition V S M
Key Requirements Billing and shipping Must be in the same month Transport Weight Rqmts (DOT) 4,000#/ Basket 3,500# Basket for CA (only) HF Basket / handling system (Physical /Mech) API Aware of 8 support Rqmt Maintain FIFO
Performance Metrics Quality: Order Accuracy Current : 35-65 errors / Wk Target: Less than 5 errors / Wk Delivery: Time to Pull (Single route) Current: Brownsfield Range from 3:20 - 5:30 Hobbs Range 4:45 - 7:20 Productivity: Parts / man hour Line Items / man hour
Statement of the Ideal On Demand: JIT Flow: Simple & Direct Defect Free 1 by 1 Easy & Low Cost methods
Was
Shipping Dock
Bundling Area
Ideas from the workers On Demand: JIT Flow: Simple & Direct Defect Free 1 by 1 Easy & Low Cost methods
Communications with team
Moving the racks
Current State
After Kaizen Bundling
After Kaizen MRL Stations
After Kaizen Stand Up
After Kaizen Dock Area

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  • 1. Shipping: Process to Pull MRLs & Requisitions November 2011 Kaizen Event
  • 2. Preparation Work: Establish the Need (Business case). Performance Metrics. Demand Value Statement, Key Reqmts, Collect Team Member Ideas Outline of the Week
  • 3. Day 1 : Grasp the Current State Map the current state Spaghetti Diagrams Map the Information & Material Flow Study each process step. Process cycle times, WIP, total flow time, etc Statement of the Ideal Create Future State Day 2: Big Changes (make the change) Day 3: Run the new process Day 4: Standardize & Train Stabilize new process Day 5: Report results. Outline of the Week
  • 4. Business Case Growth is expected: From $120 M to $200 M approx 15-20% / year Market Pressures Drive: Complexity Speed Quality Pricing Create a process capable of making: perfect shipments, more often, with less effort. Shipments 2010 2011 2012 Parts Shipped / month 210,000 220,000 235,000
  • 5. Value Statement What Value does the Shipping Team bring to HF and The customers? Product Knowledge JIT Delivery in Perfect Condition With product knowledegable personnel we will deliver to our customer the products when wanted, where wanted, and in perfect condition.
  • 8. Key Requirements Billing and shipping Must be in the same month Transport Weight Rqmts (DOT) 4,000#/ Basket 3,500# Basket for CA (only) HF Basket / handling system (Physical /Mech) API Aware of 8 support Rqmt Maintain FIFO
  • 9. Performance Metrics Quality: Order Accuracy Current : 35-65 errors / Wk Target: Less than 5 errors / Wk Delivery: Time to Pull (Single route) Current: Brownsfield Range from 3:20 - 5:30 Hobbs Range 4:45 - 7:20 Productivity: Parts / man hour Line Items / man hour
  • 10. Statement of the Ideal On Demand: JIT Flow: Simple & Direct Defect Free 1 by 1 Easy & Low Cost methods
  • 11. Was
  • 14. Ideas from the workers On Demand: JIT Flow: Simple & Direct Defect Free 1 by 1 Easy & Low Cost methods
  • 19. After Kaizen MRL Stations