Key tools or services
Lean Thinking / VSM, Stock Reduction, Warehouse Improvements, Error Proofing and Visual Management
The Introduction of own brand tile products at Instarmac had brought with it a change in the type of orders received. The new range required the building up of a pallet from a wide range of SKU's, compared with full pallets for existing products. This manual process had many opportunities for error and required 100% checking of picked pallets. Data showed that there were errors on 2.5% of all pallets and there were still customer complaints for incorrect deliveries.
A cross-functional team led by picme® mapped the picking process and identified possible sources of error. These included:
The steps taken to improve the process were:
100% inspection of pallets for 3 months showed a 0.25% error rate (90% reduction). Further improvements have removed the need for any checking of pallets after 6 months.
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