So What’s New?
Well, I can’t lie, I’ve been terrible in keeping up my regular blog posts. This should be the start of a new ‘era’, so to speak.
So what’s been the delay? Well apart from doing some travelling, ive just recently started a job as a Graduate trainee within an exceptionally good Lean organisation. From now on I shall be regularly updating my blog with new things i am learning, and hopefully providing examples of both good practice and bad practice that i encounter along the way. For personal reasons i won’t be divulging where i work or who the company works with, but I will hopefully be able to include true-life examples, just anonymously.
So after a brief spell of inductions and learning the company principles, our team of 4 graduates have been set a task to improve the pickface accuracy in a warehouse. Currently the accuracy is 35% lower than they would like, so we have been in a deep discovery stage to understand where these inaccuracies are occurring, and what the root cause is.
One thing which i quickly found, was that there was not just one reason, but a whole host of reasons. Reasons such as:
- Lack of standardised training
- SOPs are not clear and seldom followed
- Supplier compliance is poor
- Products known as breakpack* aren’t clearly labelled
- Stock-team firefighting by counting large amounts of stock on a daily basis
- Key terminology such as pyramid picking* just not understood
- Wrong items in pickfaces
- Items falling of LLOPs* and potentially created damaged goods.
As you can see there are a number of issues which the team must tackle in the design phase.
I shall update the blog soon with the design phase information, and explain a little more about the plans we intend to implement.
*Breakpack is a product which is shipped in a larger box, and when it is picked from a pickface, the larger box must be opened in order to pick the quantity required from inside.
*Pryamid picking is where pickers pick the boxes closest to them each time, this forms a pyramid shape, with a large stack toward the rear of the pallet, which creates an unsafe pallet. They tend to fall over as they are unbalanced, losing and breaking products.
*LLOPs are Low Lift Order Pickers.