Leaning The Warehouse
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Brian Dreckshage, CFPIM Senior Managing Consultant BKD, LLP
description
Presentation for hourly warehosue staff
Transcript of Leaning The Warehouse
Brian Dreckshage, CFPIMSenior Managing ConsultantBKD, LLP
AgendaIntroduction
Important Points
Lean Overview
Foundation – Storage Techniques
Applying Lean Tools to the Warehouse
Summary
IntroductionAbout me
What we are not going to discuss
• Inventory
What we are going to discuss:
• Application of lean tools
Important PointsTime constraints allow us to focus solely on some lean tools
Lean is a people and culture driven process…what we discuss will not make your warehouse lean
During this time, think about how you can involve your warehouse people in applying these tools
Before we start, what question do we need to ask and answer?
Why lean the warehouse?
70%1%1%28%0% 1. Everyone else is doing lean
2. We want to lower our costs in the warehouse3. I’m being pressured to do something 4. I want to change how we work so everyone does
things my way.5. We want to service our customers better
Lean Overview – the constant and relentlesspursuit of waste reductionSeven Wastes:
OverproductionInventoryRepair/rejectsMotionProcessingWaitingTransport
Foundation –Storage Techniques
Typical Warehouse Waste
Group similar items together
Use separate locations for each SKU
Clearly mark locations – aisles, racks,shelves and bins
Good and Bad Setup
Store by Velocity
Store items Vertically
Location sizes based on max inventory levels
Vertical
Not Vertical
Vertical Storage
Store items within easy reach of pickers
Store heavy items down low
How well do your storage techniques work? How long does it take you to train a new picker?
17%19%31%28%5% 1. We don’t train new pickers
2. 1-2 days3. 3-5 days4. Two weeks5. More than two weeks
Applying lean tools to the warehouse
Lean Tools- 5S
- Process Mapping
- Standard Work
- Slotting
- Cross Slotting
- Workload Leveling
5SIn a nutshell, the purpose of 5S is to clean and organize the warehouse – facility, inventory and equipment, standardize this into everyone’s daily routine, including a mechanism to sustain this as a way of life
Part of this as it applies to the warehouse is in keeping “Unnecessary” people out of the warehouse
5S?
Process Mapping
Standard WorkIn the warehouse, standard work refers to a standard operations routine
Establish the “best way” to perform various warehouse operations
Setting cycle times, etc. (if applicable) is done in workload planning
Slotting
How many of your warehouses use slotting?
23%17%13%8%40% 1. We do not use slotting
2. We have slotted once3. We perform slotting yearly4. We perform slotting monthly5. Before today, I did not know about slotting
X Slotting
Workload Leveling
Visual Control
SummaryLean tools can be applied to a warehouse
If you choose to do lean, what is the expected outcome?
Carefully choose the tools that you use, there is no definitive lean model
Lean is a people and culture driven process
