Scope of project
Create a order picking and packing system that uses handheld barcode scanners to guide warehouse workers to pick items from Kanban bins as per order. Use the existing ERP System to get data from the front office.
Goal
-Eliminate wrong item mistakes.
-Reduce walking.
-Intuitive training.
-Minimize workflow deviation.
Assessment
In analyzing the workflow of picking and packing orders in our client's warehouse, we first conducted a thorough review of current processes and gathered data on key performance indicators such as pick and pack rates, accuracy, and labor costs. Through this analysis, we identified areas of inefficiency, such as bottlenecks in the flow of goods and a lack of standardization in the picking process.
Everyone's idea matters
To address these issues, we worked closely with the warehouse managers and associates to promote inclusiveness and gather feedback on potential solutions. We implemented new processes and technologies, such as QR code scanning and real-time inventory tracking, to improve accuracy and efficiency. We also developed training programs to standardize the picking process and empower associates to take ownership of their role in the process.
Implement, Monitor & Measure
As a result of our efforts, we were able to increase pick and pack rates by 30% and reduce labor costs by 20%. Additionally, by fostering a culture of inclusiveness and collaboration, we were able to improve morale and retention among warehouse associates. Overall, our analysis and implementation of solutions helped the client to improve their warehouse operations.