Benchmarks & Client Cases
Productivity increase in Spare Parts Warehouse
The Challenge
Problem
• Low productivity amongst warehouse teams
• Suboptimal occupation of storage slots
• Unshipped lines or picking errors
• No vacancies to absorb new storage SKUs
Root Causes
• Poor visual management to support material flow
• Storage slots not adjusted to specific needs of parts
• Poor planning of team activities
The solution
• Sorting of parts on arrival according to size and storage area: small parts on mobile shelves; medium parts on trolleys; large parts on pallets
• Cross docking for parts to be shipped on the next working day
• Mizusumashi route to move storage trolleys, shelves and pallets to their future storage area/aisle
• Customised storage slots for each part: this allowed for high density of parts in warehouse
• Planning and balancing of workload through Daily KAIZEN™ and levelling box
The Results
The project had a Payback period of 3 months with annual savings of £207,000.
Warehouse space
Amount of warehouse space required reduced by 30%
Productivity
Warehouse team productivity increased by 8%
#logistics #warehousing and transport
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