Team EX

PATS

“I empower this team to follow the guidelines of Action Workout

and support all decisions that are made by the team, (as long as
it’s the Colts).”

Managers signature, Robert Wooldridge Date: 8/25/200

8

Team Members
E

Team Members:
R
TU
C

• Ed Huttunen
PI

• John Bigelow
AM

• Jamie Herman
TE

• Jennifer Byrd-Hughes
• Marcie Jaramillo
• Adam Theiss
• Gauri Bhalerao
• David Mays
Jeffersonville Action Workout Goals and
Objectives

Team Objective:
• Simplify, error proof and standardize the Export shipping
process.

Goals:
• Reduce incidents of freight forwarder/customs rejecting
shipments by 75%, (includes hazmat, invoicing, communication,
etc)
Baseline: 75% were being rejected in May, 11% in July

• Increase productivity by 20% by eliminating waste in the

export process
Baseline: 321 minutes to process a truck order…
inefficiencies in others

• Implement standard and Modify QS9000 to assure new process

is documented
Assure new packers come up the learning curve quickly
Operation Problem Actions Taken Results

Lot of steps back and Organize the stations to Eliminated 4 processes

forth between various avoid going back and and
stations to complete the forth and just go streamlined the overall
order. forward in one direction. process. 50% travel
reduction per order.

Before Kaizen After Kaizen

Before Process Map After Process Map

Picker places Packer picks Packer verifies Pick up Box
Order at the the order from parts and qty Pack parts in Picker places Packer picks Packer verifies Pick up Box Walk to the mail
conveyer 3 steps
3steps conveyer 3 steps 15 steps Box or envelope Order at the the order from parts and qty Pack parts in station
conveyer 3 steps conveyer 3 steps 3 steps Box or envelope 1 step

Print Country Of Walk to Write Measure the Weight the

Print Country Of 2steps Write Measure the 1 step Weight the
Origin Computer 1 dimensions to size of package package package
Origin dimensions to size of package
document 3 steps the order Dimensions 3 steps document the order Dimensions

3 steps

Walk to WMS 3 steps Go to Computer 2 Computer 2 – Look up prices Write prices on WMS WH109 WMS WH111
Look up prices Write prices on (bouncing)
Computer – WMS WH109 WMS WH111 (Transaction) paper (carrier info)
(Transaction) paper
(bouncing) (carrier info)

Pick up packing WMS WH111 WMS WH111

Walk 2 steps to Label gets printed WMS WH111 WMS WH111 Input Wt and (carrier info)
Pick up packing A slips
Input Wt and (carrier info) dimensions
slips Genicom printer Stick Labels
dimensions
2 steps

A
After Process Map
Put labels on the
A
Before Process Map A
Pick up Country
of Origin
Label gets printed
Stick Labels
package

Put labels on the

Go to Computer 1 Pick up Country Label gets printed 3 steps
package
of Origin Stick Labels
5steps 2steps
Pick up FedEx Label gets Weigh and input Walk to Fed Ex
Commercial printed details Machine
10 steps Stick Label
Invoice
Pick up FedEx Label gets Weigh and input Walk to Fed Ex
Commercial printed details Machine
Invoice Stick Label

Fold paper and 3 steps Walk to WH117- Input Scan Order

put in plastic Computer2 tracking Info
envelopes
Fold paper and 10steps Walk to WH117- Input Scan Order
put in plastic Computer2 tracking Info
envelopes
19 steps File Order Order Complete-
F6

65 steps File Order Order Complete-

F6
30 processes
34 processes
Operation Problem Actions Taken Results

Required lot of steps Got all the stations Reduced number of

back and forth between closer to reduce number steps needed to process
various stations to of steps needed to an order by 45%
complete the order. complete the order.

Before Kaizen After Kaizen

Spaghetti Diagrams
7 ways design:
2 3
1
Operation Problem Actions Taken Results

The area was Implemented 5S to Made the area

unorganized, and it was organize the cleaner, and easier
difficult to find what you workstation area. to find items
needed. creating better
flow.

Before Kaizen After Kaizen

Operation Problem Actions Taken Results

Exporters would have to Moved the scale to Eliminated 6

turn around and carry make the process footsteps for each
the box to the other flow. box
workstation to weigh - Eliminated the
items. need to pickup and
carry each box to
another station.
Before Kaizen After Kaizen
Operation Problem Actions Taken Results

There were 2 Genecom - Setup new routine to - Cost savings TBD

printers there were print the Packing lists on for printing
printing BOL and the Laser printer Packing Lists
Packing List reports. - Removed the Genecom - Reduced 15
They were bulky and printer, and moved footsteps to access
were taking up valuable copier closer to point of the copier.
space. use.
Before Kaizen After Kaizen
Operation Problem Actions Taken Results

To ship FedEx orders, Loaded the FedEx Reduced 20 steps

another computer was software onto the needed to perform
needed and additional other stations and a FedEx shipment.
steps were required to moved the label
walk around to access printer.
it.

Before Kaizen After Kaizen

Operation Problem Actions Taken Results

- Workstation 2 was -Loaded all -Items are easier

cluttered and it was not software needed to to find.
easy to find items to process fully function on its -2 exporters can
the orders. own work on processing
- This workstation was used -5S the area orders at the same
only to create 1 report and time
process DHL orders
Before Kaizen After Kaizen

DHL label
printer and
DHL and
scale
FedEx label
printers and
scales
Operation Problem Actions Taken Results

- Workstation pc’s start -All necessary -Click path

menu was disorganized. applications were reduced
Programs were in individual organized on start -Simplified
folders. menu navigation

Before Kaizen After Kaizen

Operation Problem Actions Taken Results

It would take over 2 Implemented 20% reduction in

hours to audit a truck alphanumeric sort audit process on
load before processing in the report to find large, multiple
parts quicker page truck orders

Before Kaizen After Kaizen

Operation Problem Actions Taken Results

It required a lot of steps Developed a cart to Reduced 35%

back and forth to put move the stickers footsteps of steps
the stickers on the to the boxes they required to label
boxes, and they were need to be placed the truck orders
not organized. on.

Before Kaizen After Kaizen

Prototype

Finished Product
Operation Problem Actions Taken Results

- The area was cluttered -Moved the copier -Reduced 10

and was difficult to walk -Split the phone footsteps to access
around. line the copier
- The copier was difficult -Removed the -Eliminated time
to access and shared a sticker table needed to change
phone line with the the phone line
FedEx line
Before Kaizen After Kaizen
Operation Problem Actions Taken Results

Excess items were being 5S the area Only storing items

stored in the back area, that are needed,
and were no longer and freed up 225
being used. sq ft

Before Kaizen After Kaizen

Operation Problem Actions Taken Results

A conveyor and filing Removed the Orders are

system were taking up conveyor and filing organized in lanes,
valuable space in the system to create and are easier to
work area lanes for both truck process and load.
orders and small
pack orders

Before Kaizen After Kaizen

Operation Problem Actions Taken Results

It required 20 footsteps -Freed up 75 sq ft. to

Moved the packing create flow in the
to access the packing material to be process.
material and bring it closer to the -Eliminated 15 footsteps
back to the workstation. workstation per order
-Removed 50% of
packing material and
shelving.
Before Kaizen After Kaizen
Jeffersonville Action Workout Target Sheet
Kaizen Newspaper
% COMPLETE
ACTION ITEM
DATE TARGET
OWNER

100%
ASSIGNED COMPLETION

50%

75%
25%
Short Term Audit Query Huttunen 27-Aug 5-Sep X
Laminate Instruction Notebook Huttunen 27-Aug 29-Aug X
One Page "walkup" Cheat Sheet Huttunen 27-Aug 4-Sep X
Spec for Long Term WMS Audit Huttunen 27-Aug 12-Sep X
Spec for WH based Commercial Invoice Huttunen 27-Aug 5-Sep X
Buy cable for FedEx Printer Mays 27-Aug 28-Aug X
Datamine for long term JAVA based Audit Huttunen/Mays 27-Aug 5-Sep X
Byrd-
Build Cart for Labels 26-Aug 29-Aug X
Hughes,Bhalerao,Theiss
Allocate CoO DB on both Workstations Bhalerao,Theiss 26-Aug 29-Aug X
Setup a DETA account with UPS for Worldship Elrod 28-Aug 5-Sep
 Export Action
Workout 2008

Lessons Learned
Jeffersonville Action Workout Lessons
Learned
Ergonomically/LEAN Functional Setup
What worked well in the past, became suboptimal over time.
Incremental work arounds were the answer as business
requirements changed

What we saw we needed to do when we stepped back:

– Reorganize existing Setup to increase efficiency/safety for

the individual export packer.

– Decrease travel time required to process orders

Jeffersonville Action Workout Lessons
Learned

Increased Efficiency

– Consolidate Computer Workstation Usage to 1 Terminal

– Minimized Waste, (motion, set ups)

– Improve safetiness, (no clutter, ergo friendlier)

Awesomeness factor increases, better quality too!

Jeffersonville Action Workout Future
Vision

Vision…….

Set the groundwork for future and

continuous improvements…..want to
look like the domestic air and ground
pack lanes.
Questions?