project on productivity improvement

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Productivity Improvement Plan

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Page 1: Project on Productivity Improvement

Productivity Improvement Plan

Page 2: Project on Productivity Improvement

Revisiting Process & Productivity Benchmarks, plan to reduce Complexities.

Focus shifted from Average Productivity to Person wise Hourly ProductivityTracking.

To eliminate Low Productivity Hours – Minimize Startup time & Lunch Break Time.

Identification of Grade wise Performers, Rewards for High Performer &Counseling/ Training for Low/ Medium Performers. To be reviewed every fortnight.Picking, Put away & Sorting on individual basis and Team wise tracking for Inward,Outward & GPS.

Daily Display of High & Low Performers in their respective areas and briefing at thestart and end of the shift.

Project wise accountability assigned.

To ensure accurate inventory by putting enough control/ Checks and dailyreconcilliation.

Separate Team for Quality / Excellence and Exception Management.

Productivity Improvement

Page 3: Project on Productivity Improvement

Inward Department:

Concern: Overall productivity getting affected due to: Time Lag between Vehicle change over at the Docks. Mixed vehicles taking longer time to unload. Issues related to Import Container. Delay in X- Doc allocation during Peak. LC Stocks waiting time at Stage is more then a day.

Plan: Productivity Tracking for GM & Apps separately .(Started from this week.) To reduce time lag for vehicle changeover: (Started from this week)

o Additional vehicle placed at the Dock 15 mints before First vehicle Unload.oSupervisor to print out QC Report and arrange for Pallets/ Stage before vehicleunload starts.oWith more staging area available now for Apps, Stage stocks to be moved to stdArea & X-Doc Area ( Now defined) for further Processing so that the Dock Stage areais always available for vehicle Unload.

Concern and Plan

Page 4: Project on Productivity Improvement

Inward: With the start of NEP, the Mixed vehicle cases should reduce. Feed back to SCS isbeing Provided for rest of the vehicles.

Define limit to PO/SKU/XD/STD/Format/Vendor mixing proportion to arrive at a optimal unloading benchmark condition, and monitor the real unloading and Dock TAT productivity. Will complete this activity in two weeks by 29th Feb.

For Import Containers : Advance allocation & Inbound release from SCS Team.

Need support from IT Team to ensure minimal delay in X- Dock allocation. Change in Process for X-Doc to be initiated.

Balancing of X-Doc & Standard ASN, During peak maximum X-Doc on any given day should not exceed 60%. Already discussed with Sankat & Team.

LC Stocks – Now the stocks are expected for BB & BF Only. Change in Process from SO/ PO Process to intercompany PO ( ZTSP Document Type, already discussed with Sankat & Team)

Concern and Plan

Page 5: Project on Productivity Improvement

Put away Department:

Concern:Insufficient HPTS at all the shelving Floors increases idle Time, as the PalletMovement from Unloading gate to aisle is also done by the Put away person. in high depth bins transaction increases with no. of boxes, ( No of locations remainsless) Time spent in resolving discrepancies.Frequent Zone alignment , inter movement of Stocks.Aisles getting choked in Racks with Picked up stocks.

Plan: Dedicated resources for FRL & FLFL with complete accountability.Additional HPT’S to be inducted in shelving's (Indent raised from our end)Review time & motion for this activity and redefine benchmark which is currently 60box per hour. To be completed by 20th Feb.Discrepancy resolution to be routed through Inventory Audit Team separately.Increase Putaway Audit to 30% once the New HHT Comes in. Revisited Material Flow to ensure clutter Free Aisles. Focus to move the stocksimmediately to packing area & GPS.

Concern and Plan

Page 6: Project on Productivity Improvement

Picking (Shelving): Champion - Iliyash & KishoreConcern:Insufficient crates for Batch Pick – With 1.5 times crate turns per shift Pick task getsrestricted to 6000 task only, for which picker either need to wait or work in extendedshifts. Short tasks & Inventory inaccuracy.

Plan: Increase the crate Turn Per shift to two Per shift.

o Load balancing across all the PTL Zones and PTL to run with all the six Zones.o 2nd Shift for PTL during peak load to manage X-Doc & Batch Pick.oBatch Pick to happen in only one shift.o2000 New Crates to be inducted in system.

Short tasks to be minimized and inventory accuracy to be increased.o Picking & Put away Audit % to be increased to min 30%.oDaily short task analysis & Correction on the same day.o Hourly monitoring & daily feedback.

Concern and Plan

Page 7: Project on Productivity Improvement

Picking (Racks): Champion – Srinidhi

Concern: Each/ IP Picking from Racks reduce Picking Speed.Choked Aisles due to lag in material flow, Insufficient HPT’s & Choked GPS.Left over of tail stocks increases no of Pick Location.Short task/ Inventory accuracy.

Plan:Orders are being taken for Old SKU lying in Racks (Tail Stocks) but picked in IP/EA forclearance.Space created for mapping SKU’S to shelving which are Picked in IP/ Each.Material Flow maintained for Clutter free aisles.Hourly/ daily monitoring & Feed back. To minimize short task & Ensure 100% Inventory accuracy.With installation of Sorting Racks for GM the productivity of X-Doc Break pack forGM will Improve. Will start from 17th Feb.

Concern and Plan

Page 8: Project on Productivity Improvement

PTL :

Concern: Frequent change over of Zones due to shortage of HHT. Imbalance Load across all the Zones, which leads to lower utilization. Server capacity issue leads to data low error & Invalid Boxes.

Plan:

Picking/ Sorting & X-Doc all aligned for load balancing.With Induction of new HHT’S will be able to run all the Six Zones simultaneouslywithout frequent changes.Need IT support to overcome server capacity issues.

Concern and Plan

Page 9: Project on Productivity Improvement

GPS :

Concern: Staging area for keeping store sorted material was a major concern in GPS. Data accuracy is a concern as this activity is not captured in system.Time lag between cluster sorting and Store sorting due to PTL shifting.

Plan:After PTL shifting & Outward from both the sides GPS has been Decongested. More DSD Lanes has been allocated for keeping ready stocks.With the induction of 3 BOPTS by 5th March, the time lag will be reduced to an extent.Monitor productivity separately manually both for cluster and store sorting in Apps and non Apps. Correct material flow will enhance productivity.

Concern and Plan

Page 10: Project on Productivity Improvement

Outward :

Concern: Issue in availability of packed boxes from GPS due to delay in sorting & tracing the Boxes.Cluster Vehicle loading takes longer time due to LR Sticker pasting in every Boxes.Delay in getting SAP DC & Way bill generation.

Plan: Two major clusters Kulana & Neelmangla shifted to the other side. 100% Sorting will be ensured for these clusters.With Decongested GPS & DSD lanes for packed stocks, the packed stocks can be retrieved more efficiently.Productivity for DSD & Cluster Vehicle will be measured separately.

Concern and Plan

Page 11: Project on Productivity Improvement

Inward: Measuring real time current productivity for all types combination vehiclesseparately and define slab for productivity benchmark.

Put away: Measuring real time current productivity for shelving put away .Implementation of packing in packing area only and not in aisles.

Picking: Picker wise display of weekly productivity trend with highlighting low andhigh performer. Addressing low performer on daily briefing. Identifying each pick skuin rack and moving to Shelving.

PTL: Allocation of picker as per % allocation in Men’s/Ladies/Kid’s, so as to getcontinuous flow in PTL for sorting.

GPS: Indentify stores that can be moved to cluster in consultation with SCS team, sothat all DSD stores can have lanes allocated.

Outward: Measuring real time current productivity for DSD and cluster vehiclesseparately considering vehicle size.

Projects identified

Page 12: Project on Productivity Improvement

• Started displaying

productivity trend for

previous week, and

addressing in daily briefing.

• Identification &

Counseling of low

performer and knowing

their constraints.

• High performer will be

appreciated and motivated

with small rewards like

chocolates for maintaining

consistency and further

improvement.

Productivity tracking