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PLANNING & ANALYZING:
STEPS & EVALUATION METHODS
Evaluate solutions to operational challenges through strategic planning, historical review, data analysis, review of peak period challenges, and scientific comparison of alternatives.
- Develop a strategic plan for your operation
- Document experience: learn from the past
- Review bottlenecks, labor issues, timeliness, accuracy
- Crunch time: What went wrong when you were really busy?
- Order history: key to simplifying your processes
- Low cost alternatives versus capital investment
- Methods to objectively evaluate your options and payback
- Prioritize opportunities: cost, savings, time, risk, practicality
1ST TEAM ACTIVITY:
BREAKOUT TEAMS EXPLORE A
VARIETY OF DISTRIBUTION TOPICS
The first of two team networking opportunities: Forum participants select their topic and participate in a lively discussion with other attendees. Each team shares their findings and recommendations with the group at large.
CREATE/OPTIMIZE YOUR LAYOUT:
Facility design principles, space management, equipment and automation, creating winning layouts. Good layout simplifies product flow and reduces operational costs. Understand the critical elements for creating or modifying layouts to create a world-class facility.
- What is feasible? Constraints that affect layout options
- Create good-looking layouts that are easy to manage
- Pick the best size, shape, and ceiling height
- Simplify product flow to increase productivity
- Make the most of your available floor space – squeeze more out of what you have
- Control functional adjacencies – minimize movement and travel
- Evaluate racking, shelving, and mezzanine options
- Incorporate conveyor and automation intelligently
TAKE CONTROL OF YOUR STOCK: MANAGING INVENTORY AND CHANGING STOCK REQUIREMENTS
How to improve your in-stock performance and eliminate items that don’t make money. Methods for condensing stock and reducing stock handling labor.
- Does your current inventory mirror your customer needs?
- Perform an ABC analysis – 20% of your stock is 80-95% of your business
- Optimize stock levels based on historical and forecasted data
- Reduce replenishment; optimize labor to manage inventory
- Alternatives to storing certain products in your facility
- Create intelligent slotting with unit and cubic velocity
- Best practices for maintaining high levels of inventory accuracy
- Inventory equipment options
- Strategies to optimize management and storage of inventory
LOW COST OPPORTUNITIES THAT PAY LARGE DIVIDENDS
Physical facility improvements, improvements in ergonomics, employee training, and better communication don’t cost a lot to implement, yet can result in substantial savings.
- Lighting, Floor Marking, Signage, and Location Schemes
- Why investing in ergonomics can save you money
- Improve your Documentation and Training
- Integrate associates into operational improvement
- Improve overall operational flexibility
- Work smarter: take advantage of common characteristics
- Don’t Overdo! Use only as much technology as is justified!
2ND TEAM ACTIVITY:
ROUNDTABLE DISCUSSION TOPICS
The second of two team networking opportunities: Select a roundtable topic and share ideas, concerns, and solutions. Roundtable topics offered will be based on input received prior to the forum.
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DEPLOYING WORLD-CLASS ORDER SELECTION
Typically the lion’s share of payroll, order selection activities merit special attention. A look at order organization, order batching, order flow, ergonomics, product slotting strategies, and methods to leverage paper-based picking. Explore current order selection technology and software.
- The most important elements in order selection efficiency
- Techniques for maximizing small order selection productivity
- Strategies for order flow: Pick and Pass, Parallel Pick, Pick and Consolidate
- Optimize slotting: random vs. fixed location strategies
- Optimize your existing paper system for greater performance
- Picking ergonomics and the “golden zone”
- Differentiating single line orders, small orders, large orders
- Maximize pick rates: reduce footsteps & increase pick density
- When to use carts, powered vehicles, totes, conveyor, and consolidation Equipment
- Weighing automation against operational flexibility
- Cross docking and “Put” systems
- RF Scanners, Pick to Light, Voice Directed Picking, AS/RS Systems, A-Frames, Sorters
CREATING A WORLD-CLASS PACKING AND SHIPPING AREA
Like order selection, the packing area can have a large payroll. It’s often the #1 area creating facility bottlenecks during peak periods. Strategies for improving order delivery to pack, order management, ergonomics, labor management, and verification options. Technology options that can help, including box making, labeling options, void fill options, in-line options, and completed order sortation.
- Manage uneven workload and labor requirements
- Plan order delivery to maximize packing efficiency
- Visual order management strategies at the packing area
- Order verification and QC options
- Improve ergonomics and plan efficient flow
- Comprehensive review of void fill alternatives
- Using conveyor intelligently
- In-line packing and manifesting systems
- Other technology options: Literature insertion, labeling, box making, box sealing
MEASURE AND IMPROVE PERFORMANCE: BENCHMARK, TRACK, AND COMMUNICATE
Benchmarking enables you to objectively compare your operation to another similar one, letting you focus on those areas that are under-performing. Explore the basic principles of benchmarking, and strategies for deploying performance-based improvements within your facility.
- What is benchmarking?
- Where can you get benchmarking data?
- What should you compare your operation to?
- What are the key performance indicators you should be measuring?
- Establishing suitable standards
- Communicating the benefits of productivity improvement
- Create a dashboard for collecting and summarizing performance data
- Weigh teamwork vs. individual performance
- Establish work standards and tracking of performance against them
- Employee incentive programs and principles of gain sharing
EVALUATING SOFTWARE OPTIONS: ERP, WMS, WCS, AS/RS, VOICE, PTL, MANIFESTING, ETC.
Evaluate software options and choose the ones that make the most sense for your operation. Assess risks and rewards and choose those options that promise the best return.
- How to identify the hidden risks in some software choices
- Do you need an ERP, WMS, or WCS System?
- Special advantages of order selection systems (Pick to Light, Voice, RF Scanners)
- When to choose an order selection system vs. a WMS or ERP
- What are the organization benefits and demands of various software systems?
- Solutions that maximize returns and minimize risk
- Blend manual systems with software-based improvements
- What are the benefits of manifesting software, and what options are available?
- Tracking performance and workforce management software
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