LEANING THE WAREHOUSE

DISTRIBUTION TEAM MEETINGMARCH 7, 2008

Lean Overview – the constant and relentless pursuit of waste reduction

Overproduction Inventory Repair/Rejects Motion Processing Waiting Transport

IMPORTANT POINTS

Lean is a people and culture driven process…

Ask yourselves how you will involve yourself everyday making our warehouse lean…

What tools do you have or do you need to accomplish our goals…

OVERPRODUCTION

We have addressed this with going to an FGI Kanban

More important then ever for MH’s to have 100% Put-away accuracy, 100% pick accuracy and meet pick times for each PRDO

INVENTORY

Receiving quality raw material, putting them in the right place, at the right time, at the right cost.

Consolidate like items Store heavy items down low if

possible Store items safely on good skids

REPAIR/REJECTS

While we have made great progress in reducing rejects (scrap), we have to make further progress

When you are picking, are you asking yourself is this how I would move it if I owned it?

Think twice, pick once

MOTION Wave pick by sequence all the time Prioritize your Kanban cards by

sequence…take 5 minutes to organize your work

Use your technology (ie: RF Guns, scan receiving labels instead of hand keying, scan location tags)

Pick your equipment based on your work (ie: reach truck, sit down lift, cherry picker)

PROCESSING

Never move a product physically unless it moves systematically and vice versa

Never combine unlike SKU’s on the same pallet in location unless each item is clearly marked

Know what you are picking/putting away, if you are unsure, ask

WAITING

If you run into a problem and you are unable to get immediate help, move on, and go to the next item (do not plug in a ‘SWAG’), you are likely to forget about it and it will be too late to correct it before it impacts other operations

There are always other 5S tasks to complete everyday

TRANSPORT Always pre-trip and post trip your

equipment. Never use a piece of equipment

that needs repair Always yield to pedestrians Always honk your horn when you

start moving or change direction Follow all safety signs in the facility

TOOLS

5 S Standard Work Cross Slotting Workload Leveling