SAMPLE DRAWINGS
Conventional Warehouse Design
Conventional Warehouse Design
Factory Automation Buffer Design
Factory Automation Buffer Design
Small Distribution Automation Design
Large Distribution Automation Design
SAMPLE DATA ANALYSIS
Sample Data: SKU Activity
SKU Activity for Full Case Pick for 2005
Top 70: The top 70 SKUs represent 61% of case activity in the DC, these are considered Code #1 or High Movers, located on top of the mezzanine.
The next 272: The next 272 SKUs represent 31.7% of case activity in the DC, these are considered Code #2 or Medium Movers, located below the mezzanine.
The next 201: The next 201 SKUs represent 5.3% of case activity in the DC, these are considered Code #3 or Slow Movers, located in the warehouse in the pallet rack.
The rest: The rest of the SKUs represent 2% of case activity in the DC, these are considered Code #4,5,& 6 or Super Slow Movers & Specialty items, located in designated locations at floor level in the pallet rack, floor locations, and above the offices.
98.0% 92.7% 61.0% 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 1 140 279 418 557 696 835 974 1113 1252 1391 SKU Sequence in Order of Activity Number of Cases Picked per SKU 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0% Cum % of Activity Summation Of Full Cases Picked Cum % of Cases Picked 10% 20% 30% 40% 50% 60% 70% 80% 90% Confidential
Sample Data: Full Case Pick
Summation Of Full Cases Picked Cum % of Cases Picked
76.2% 89.5% 95.4% 98.2% 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 1 140 279 418 557 696 835 974 1113 1252 1391 SKU Sequence in Order of Activity Number of Cases Picked per SKU 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0% % of Total SKUs Cum % of Activity
10% 20% 30% 40% 50% 60% 70% 80% 90%
Sample Data: Partial Case Pick
94.0% 97.2% 89.1% 81.5% 71.5% 57.3% 38.8% 0 1,000 2,000 3,000 4,000 5,000 6,000 7,000 8,000 9,000 10,000 1 91 181 271 361 451 541 631 721 811 SKU in Order of Activity Sequence Bottles Picked from Partial Cases per SKU 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0% Total % of SKUs Cum % of Activity Bottle Qty Picked-Partial Cases Only Cum % of Activity of the Total Bottles Picked 10% 20% 30% 40% 50% 60% 70% 80% 90%
Sample Data: Picks per Day
0 500 1,000 1,500 2,000 2,500 3,000 12/29/04 1/3/05 1/8/05 1/13/05 1/18/05 1/23/05 1/28/05 2/2/05 2/7/05 2/12/05 2/17/05 2/22/05 2/27/05 3/4/05 3/9/05 3/14/05 3/19/05 3/24/05 3/29/05 4/3/05 4/8/05 4/13/05 4/18/05 4/23/05 4/28/05 5/3/05 5/8/05 5/13/05 5/18/05 5/23/05 5/28/05 6/2/05 6/7/05 6/12/05 6/17/05 6/22/05 6/27/05 7/2/05 7/7/05 7/12/05 7/17/05 7/22/05 7/27/05 8/1/05 8/6/05 8/11/05 8/16/05 8/21/05 8/26/05 8/31/05 9/5/05 9/10/05 9/15/05 9/20/05 9/25/05 9/30/05 10/5/05 10/10/05 10/15/05 10/20/05 10/25/05 10/30/05 11/4/05 11/9/05 11/14/05 11/19/05 11/24/05 11/29/05 12/4/05 12/9/05 12/14/05 12/19/05 12/24/05 12/29/05 Picks per Day Number of Case Picks Number of Bottle Picks Total Number of Picks Metric Number of SKUs Number of Case Picks Number of Bottle Picks Average 1,497.23 718.30 779.11 Std Dev 650.30 317.15 348.57 1st Sigma 2,147.53 1,035.45 1,127.69 Min 3 1 0 Max 4137 1976 2161
0 5 10 15 20 25 30 35 40 12/29/04 1/3/05 1/8/05 1/13/05 1/18/05 1/23/05 1/28/05 2/2/05 2/7/05 2/12/05 2/17/05 2/22/05 2/27/05 3/4/05 3/9/05 3/14/05 3/19/05 3/24/05 3/29/05 4/3/05 4/8/05 4/13/05 4/18/05 4/23/05 4/28/05 5/3/05 5/8/05 5/13/05 5/18/05 5/23/05 5/28/05 6/2/05 6/7/05 6/12/05 6/17/05 6/22/05 6/27/05 7/2/05 7/7/05 7/12/05 7/17/05 7/22/05 7/27/05 8/1/05 8/6/05 8/11/05 8/16/05 8/21/05 8/26/05 8/31/05 9/5/05 9/10/05 9/15/05 9/20/05 9/25/05 9/30/05 10/5/05 10/10/05 10/15/05 10/20/05 10/25/05 10/30/05 11/4/05 11/9/05 11/14/05 11/19/05 11/24/05 11/29/05 12/4/05 12/9/05 12/14/05 12/19/05 12/24/05 12/29/05 Orders Picked per Day Orders per Day Average Orders per Day 1st Sigma Metric Orders per Day Average 15.11 Std Dev 5.32 1st Sigma 20.43 Min 1 Max 38
Sample Data: Order per Day
Sample Data: Order Profile
*Note: Average & Std Dev used is from orders with both full & partial case picks
Partial Case Lines Picked 0 50 100 150 200 250 300 350 400 359 718 1077 1436 1795 2154 2513 2872 3231 Orders in Sequence of Number of Lines Number of Partial Case Lines Picked Partial Case Lines Picked Full Case Lines Picked 0 50 100 150 200 250 300 350 400 359 718 1077 1436 1795 2154 2513 2872 3231 Orders in Sequence of Number of Lines Number of Full Case Lines Picked Full Case Lines Picked Full Case Pick Lines Partial Case Pick Lines TOTAL % 3,587 90.3% 363 363 9.1% 21 21 0.5% 3,971 174,403 195,300 369,703 47.04% 52.68% 99.73% 897 897 0.24% 120 120 0.03% 370,720 115.1 69.9 185.0
3,587 Count of Orders w/ Full Case Lines Only % Breakdown of Full & Partial Case Lines Count of Orders w/ Partial Case Lines Only Total Number of Orders Total Number of Lines in Orders w/ Full & Partial Case Lines Metric Count of Orders w/ Full & Partial Case Lines Total Number of Lines in Orders w/ Full Lines Only Total Number of Lines in Orders w/ Partial Case Lines Only Total Number of Lines Average Number of Lines in Orders w/ Full & Partial Case Lines* 115.1 1st Sigma - Number of Lines Std Dev of Number of Lines in Orders w/ Full & Partial Case Lines 69.9
SAMPLE FLOWS
A
Sample Flows: Process Flow Chart
Consolidate Pipe to Routes & Trucks
AREA B
BULK AREA
WIRE AREA PIPE AREA
Consolidate Pallets to Routes & Trucks
AREA
Receiving Verify Invoice against Received Material Move to Putaway Putaway In A Area Replenish Putaway in B Area Putaway In Bulk Area Putaway In Wire Area Putaway In Pipe Area Replenish Replenish Pick Pick Pick Pick Pick Are there any more picks in A Yes Are there any more picks in B Yes No No Are There any picks in Bulk What is Size of Order? Carton Size Sort by Zip Code Pallet Pallet Required Are there any more picks in Bulk? Yes Place in Carton Stretch Wrap Are there any more picks in Wire? Yes Are there any more picks in Pipe? Yes Stage Outside Is this order for a Branch Store? No Place in Green Store Container Move to Truck Load Branch Trucks Stage Route #1 No Stage Route #2 Stage Route #3 Stage Route #4 Stage Route #5 Stage Route #6 Sort to Truck Move to Stage Area Move to Sort Area Stage Route #1 Stage Route #2 Stage Route #3 Stage Route #4 Stage Route #5 Stage Route #6 Sort to Truck Move to Sort Area Move to Truck Load Trucks Move to Truck Move to Wrapper Are t here Picks in B for this order? Yes
Print Label Place Label on Pallets
Inspect Invoices to Pallets Are orders correct? Correct Order No yes No No
Sample Flows: VA / NVA Touches & Flows
A Area & Flow Rack Picking Receiving Wire Storage & Picking Bulk Storage & Picking B Area Shelving & Picking Branch Store Staging Branch Store Loading Small Order Staging Truck Loading Pipe Order Staging Pipe Storage & Picking Stretch Wrapping Route Staging Truck Staging Wire Order Staging 1 2 3 4 5 7 8 9 10 11 12 13 14 6 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108
What is a VA/NVA Flows?
1. Follow the path of a typical part as it flows from receiving through shipping in a typical order.
2. Record every step where the product is touched or an action is taken upon it.
3. Identify each touch as a “Value-added” or “Non Value-added” touch.
1. Receiving
2. Verify received material against
3. Print Labels
4. Apply labels to pallet/carton
5. Separate items between A, B, Bulk, and Wire
6. Move products to specific putaway areas
7. Putaway items into rack position
8. Walk down pick aisles to identify SKUs that require replenishment
9. Identify replenishment SKU
10. Pull SKU from putaway position
11. Place SKU into pick position
12. Get order form
13. Go to “A” pick area
14. Get Tote
Repeat 15-17 for 4 lines per Order in Area A
15. Read order form for 1st pick
16. Go to SKU location
17. Pick & place SKU into tote/pallet
27. When order is complete in zone past to next zone or push onto take-away conveyor
Automated: If orders are ins Area B, a pusher pushes the tote into Area B
28. Get Tote
Repeat 29-31 for 2 lines per Order in Area B
29. Read order form for 1st pick
30. Go to SKU location
31. Pick & place SKU into tote/pallet
35. When order is complete in zone past to next zone or push onto take-away conveyor
Automated: Order/Tote is conveyed to end of conveyor
36. Determine if order is a
a. Branch order,
b. small order,
c. Or to be palletized and continued into the bulk area.
Branch Orders:
37. Pick up order from conveyor and move to specific branch container
Small orders:
38. Pick up order from conveyor and move to small order area
39. Get MT carton
40. Place order in carton
41. Close carton
42. Place order label onto carton
43. Place carton onto shelf for the specific Zip Code
Orders with picks in bulk areas:
44. Get MT pallet
45. Pick up order from conveyor and move to pallet.
46. Get pallet with forklift
Repeat 47-51 for 3 lines per Order in Bulk Area
47. Read order
48. Move pallet to bulk areas for picks
49. Locate pick
50. Pick specific qty of SKU
51. Place pick on Pallet
62. When order is complete move pallet to stretch wrappers
63. Stretch wrap pallet
64. Place pallet on floor in order of Route
65. QC to inspect each SKU on pallet (9 SKUs)
66. Repeat 65 for 8 more SKUs
74. Manually sort invoices by trucks
75. Move and sort 2 pallets per order by trucks in routes as designated by #69
For Wire Area
77. Read order
78. Get Pallet
79. Go to Location
80. Get wire spool (pick wire)
81. Get empty wire spool
82. Place onto wire spooler to measure required amount
For Wire Area
83. Measure wire
84. Cut wire
85. Disassemble spooler
86. Place measured wire spool onto pallet
87. Move take-off spool back to original pick location
88. Tag measured spool
89. Move pallet to stage location
When orders are complete
90. Sort pallet to correct delivery truck
For Conduit Piping Area
91. Read order
92. Go to location /w forklift
93. Select required qty of pipe (pick pipe)
94. Tag Qty picked
95. Move picked qty to outside cantilever rack
96. Place pipe onto cantilever rack
Sort Conduit Piping
97. Find specific order/Truck/Route pick in Piping area
98. Place onto dock in order of Truck
Load Trucks
99. Find specific orders by truck location in Bulk
100. Get 1st pallet from A, B, & Bulk area
101. Place onto truck
102. Get 2nd pallet from A, B, & Bulk area
103. Place onto truck
104. Find specific orders by truck location in Wire Area
105. Get pallet from Wire Area
106. Place onto truck
107. Get Piping for order
108. Place onto truck
Sample Flows: VA / NVA Touches & Flows
Added Touch Non Value Added Touch = 11 = 97 Total Touches 108
Summary
Value
Touch