ABVI Process Improvement Team Adam Kelchlin Dave Netti Jeff Sweet Dan Brauksieck Chris Sinclair.
Post on 22-Dec-2015
213 Views
Preview:
Transcript
ABVI Process ABVI Process Improvement TeamImprovement Team
Adam KelchlinAdam KelchlinDave NettiDave NettiJeff SweetJeff Sweet
Dan BrauksieckDan BrauksieckChris SinclairChris Sinclair
Credit to National Credit to National Science Foundation Science Foundation
(NSF)(NSF) This material is based upon work supported by the This material is based upon work supported by the
National Science Foundation under Award No. BES-National Science Foundation under Award No. BES-0527358.0527358.Any opinions, findings, and conclusions or Any opinions, findings, and conclusions or recommendations expressed in this material are those recommendations expressed in this material are those of the author and do not necessarily reflect the views of the author and do not necessarily reflect the views of the National Science Foundation.of the National Science Foundation.
Needs of SponsorNeeds of Sponsor
Increase order accuracyIncrease order accuracy
Increase efficiency of Drop Increase efficiency of Drop Shipment ProcessShipment Process
Simplify process for blind and Simplify process for blind and visually impaired workforcevisually impaired workforce
Iterative ApproachIterative Approach
5 Why Analysis5 Why Analysis
Eliciting Customer NeedsEliciting Customer Needs
On-site customer interactionOn-site customer interaction
5 Why Analysis5 Why Analysis
Why is there a need for the project?Why is there a need for the project?– To Improve Customer SatisfactionTo Improve Customer Satisfaction
Why is there a need to improve customer Why is there a need to improve customer satisfaction?satisfaction?
– Orders are being filled incorrectlyOrders are being filled incorrectly Why are orders being filled incorrectly?Why are orders being filled incorrectly?
– Team members are incorrectly filling ordersTeam members are incorrectly filling orders Why are team members incorrectly filling Why are team members incorrectly filling
orders in the Drop Shipment Area?orders in the Drop Shipment Area?– The layout is inefficient and the process is The layout is inefficient and the process is
error proneerror prone
Eliciting Customer Eliciting Customer NeedsNeeds
Met continually with project sponsorMet continually with project sponsor
Gained input from ABVI team membersGained input from ABVI team members
Sensitivity TrainingSensitivity Training
Customer Feedback – Order Customer Feedback – Order Discrepancy ReportDiscrepancy Report
On-site InteractionOn-site Interaction
Time StudiesTime Studies
MeasurementsMeasurements
Current Operating ProcedureCurrent Operating Procedure
Quantifying Customer Quantifying Customer NeedsNeeds
Mission StatementMission Statement
Objective TreesObjective Trees
QFDQFD
Needs Assessment DocumentNeeds Assessment Document
Design ObjectiveDesign Objective
Mission StatementMission Statement
The mission of this process The mission of this process improvement project team is to improve improvement project team is to improve the process in ABVI’s Drop Shipment the process in ABVI’s Drop Shipment Area in order to increase customer Area in order to increase customer satisfaction, increase throughput, satisfaction, increase throughput, reduce the amount of errors, and reduce the amount of errors, and ultimately develop a system that is ultimately develop a system that is more robust and user friendly to blind more robust and user friendly to blind and visually impaired personnel and visually impaired personnel
Needs Assessment Needs Assessment
Improve Customer SatisfactionImprove Customer Satisfaction – Ship correct notepads to correct customersShip correct notepads to correct customers – Ship correct quantity of notepads to the customerShip correct quantity of notepads to the customer– Ship notepads to customer on time (Secondary)Ship notepads to customer on time (Secondary)
Improve Drop Shipment Process for blind Improve Drop Shipment Process for blind and visually impairedand visually impaired
– Redesign LayoutRedesign Layout – Redesign Process StepsRedesign Process Steps – Eliminate Ergonomic Issues (Secondary Goal)Eliminate Ergonomic Issues (Secondary Goal)
Increase Orders per day Increase Orders per day (Secondary)(Secondary)
Concept DevelopmentConcept Development
Synthesized Morphological Synthesized Morphological AnalysisAnalysis
Peer Design ReviewPeer Design Review
FeasibilityFeasibility
Pros / Cons AnalysisPros / Cons Analysis
Weighted Attribute AnalysisWeighted Attribute Analysis
Current Process Current Process AnalysisAnalysis
Standard Operating ProcedureStandard Operating Procedure
Time StudiesTime Studies
Layout DocumentationLayout Documentation
SimulationSimulation
Detailed DesignDetailed Design
New Standard Operating New Standard Operating ProcedureProcedure
New LayoutNew Layout New SimulationNew Simulation Comparison of Simulation ResultsComparison of Simulation Results
Simulation ResultsSimulation Results
Distance Traveled Reduction of Distance Traveled Reduction of 33%33%
Distance Traveled
0
0.5
1
1.5
2
2.5
3
3.5
4
4.5
5
Old Layout Distance Traveled New Layout Distance Traveled
Mil
es Miles
Simulation Results Simulation Results (cont’d)(cont’d)
Order process time reduced by Order process time reduced by 6%6% Time to Complete an Order
4.25
4.3
4.35
4.4
4.45
4.5
4.55
4.6
4.65
4.7
4.75
Old Layout Processing Time New Layout Processing Time
Tim
e (s
)
Time (s)
Simulation Results Simulation Results (cont’d)(cont’d)
Areas for ImprovementAreas for Improvement– Entering Information into the Entering Information into the
ComputerComputer– Creating ShipmentCreating Shipment– Print LabelsPrint Labels
Resource Utilization at 70%Resource Utilization at 70%
Verifying and Validating Verifying and Validating SimulationSimulation
AnimationAnimation
Simulation ExpertSimulation Expert
Pedometer ResultsPedometer Results
Time Study ResultsTime Study Results
Cost AnalysisCost Analysis
RackRack Visual ControlsVisual Controls Non-Visual ControlsNon-Visual Controls
top related