GM Shipping. Pick / Pack Process Improvement Developed, Implemented, & Presented by Reginald Fuller. Defining the Six-Sigma Project. Listen to the Voices. Voice of the Customer (VOC) On-Time Delivery Product Availability Product Selection ( IP & IQ) Quality of Shipment (Damages)
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Pick / Pack Process Improvement
Developed, Implemented, & Presented by Reginald Fuller
Wastes: Corrective, Overproduction, and Process
Wastes: Motion & Waiting
Batching Work Assignments
On-Time Route Departure & Delivery
Batch Customer Orders in Queue
Dispatch Work Assignments
Staging & Validation
Flow disruptions in the process
A typical employee walks x miles per night in dense warehouse area.
A typical work assignment takes 22.04 minutes to complete averaging 16.06 lines.
Employees consistently select from redundant locations. Redundancies account for 17.9% of total bin selections.
Employees waiting an average of 22 minutes per 8 hour shift waiting to sort materials.
Additional delays incurred from failure to complete entire batch cycle of work assignments prior to beginning next cycle.
On time departure is 77.2 with a goal of 98% for on time delivery.