Completed WMS projects
International logistic service provider
Consulting during the startup of an IT distribution warehouse
Branch
- Logistic service provider industry
- Electronics Industry
- Wholesale industry
The team warehouse logistics was asked by an international logistic service provider to act as consultant during the startup period of an IT distribution warehouse. This extensive project mainly focussed on the analysis of weak points and the realisation of suggestions for improvement.
Motive and goal
During the startup of an IT distribution warehouse various problems occurred leading to interruptions. Since the warehouse was already operating it was necessary to analyse the organisational as well as software-related processes on the site. The results should set the basis for suggestions for improvement which should then be implemented as soon as possible without causing interruptions or downtimes. The target of the project was to identify and eliminate weak points and to improve the picking accuracy and ensure the delivery reliability.
Procedure
At first the team inspected the warehouse and analysed the material flow. At the same time, staff on all levels were interviewed, i.e. from stacker drivers, pickers, group managers up to chief operating officers.
It soon became clear that there were various problems to cope with. One main reason for the startup problems were the insufficient horizontal as well as vertical communication structures. Introduction of an error protocoll (What happend when and why? How was the failure or error eliminated?) and a briefing at the beginning of the shift soon improved the exchange of information. These measures were accompanied by meetings of the team managers with and without the general management where coordination problems and tasks were discussed.
Besides the communication structures the operation was optimised as well. This included, for example, the reorganisation of single storage areas, the optimisation of the replenishment, a better labelling of storage bins and areas. Furthermore, suggestions where made how to improve the IT design and utilisation. The functions of screen masks were extended or summarized as to ensure a better utilisation or to have a better access to additional information on those screens where they are mainly used.
It was another important aspect to inspire an understanding how important each individual work package has for the overall process. For this reason, all employees participated in informational meetings and trainings during the complete project.
Result
Within a short time the main problems could be identified and first remedies were taken. A series of „small" and „large“ changes were made along the material flow chain from the goods receipt up to the goods issue. The level of information of the staff was improved drastically as was their motivation and personal responsibility.
In combination with the new communication and information structures the error ratio in picking and shipping could be reduced in line with an increase of the overall throughput. To improve the delivery reliability required by the customer all developed measures had to be taken.
