Problem : Productivity
Department : Outbound – Picking
Area identified for trailing : 4 tire area – A Zone
Suggestion :
Want to solve the problem by using method of - DMAIC - PDCA

STEPS
DEFINE Identified the problem – Productivity.
Unable to get productivity target (Outbound Sales) – 200 Line
with in 8 Hrs. Achieving Average 145 with in 8 Hrs.
MESSURE Identify the gap between current and required performance.
Gap to be achieved – min 25% more than existing .
Collected existing Daily productivity report
ANALYSE Listed out prioritize potential causes of the problem.
Usually sales team will have 3 members. Now we want picker
to be merged with Binning Team. Picker will do only picking.
IMPROVE Created simplest and easiest plan.
Test solutions using Plan-Do-Check-Act (PDCA) cycle method.
CONTROL Formatted new format for future to sustain the improvement
efficiency.
DMAIC – STEPS

PLAN Identified the
problem
WHAT
WHO
WHERE
Productivity
As a tem
Sales
For trail purpose
identified A
zone and team
Collected data
on zone ,Layout
pick type
material size
and team
members &
training
Information on
implementation shared with
respective team and
explained the purpose.
DO Segregated
data's –
On valid point
wise.
Made a new
process and
framed new format
New Process
1.Team has to
be split.
2.Timing of
picking and
packing has to
be registered.
Given training
on new
implementation
to respective
team.
Explained the
team with data
where we have
failed and due
to why. Started trailing
CHECK Measurement
on trailing
registered.
Picker started to
work
independently.
Picking start time
and end time
register happening.
Monitored on
performance
and validate
training
effectiveness.
Monitored on
Data entry on
new format.
Collected data
and suggestion
on trailing from
picker team.
Analyzing the data
registered against on trail.
ACT Reviewed
feedback.
Planned to start 2nd
phase trail.

Old Format
Date Line Challan Qty Val
New Format
Date Line Challan Qty Val
Start
Time
Close
Time
Diff

Picking – Productivity
Team capacity – 03
Team with (Outbound) – 03
Team – 02
Packer - 1
Helper - 1
Picker - 1
Present practice Suggested
Packer & Helper
Picker will be merged
with Binning Team (Inbound)
Target – 200 Lines – 8 Hrs
Achieving – 140 Lines (Avg) – 8 Hrs

Current status
Timing Not Maintaining
Manpower 3
Productivity Achieving less than 80%
Claim Unable to monitor & Control
Accuracy – Location
Inventory
Unable to control
Draw back: In current practice

Current practice
Suggested
Productivity Not Maintaining Going to Maintain
Manpower 3 2+ 1
Claim Rare Controlling Can control 95%
Location Accuracy Unable to Control Can control 95%
Inventory Accuracy Unable to Control Can control 95%
Productivity Giving 85% to 90%
Can achieve more than
100% Rare case only
will come down to 80% 90%
due to huge Qty
Benefits : After change

Old Practice (3 person a team) – Team performance report
Date Line Chl Qty Val
16.04.2014 152 32 1678 7.17
21.04.2014 150 24 1456 8.89
22.04.2014 112 16 1555 5.63
23.04.2014 115 17 598 3.86
24.04.2014 170 25 1136 10.76
25.04.2014 184 27 1369 7.03
26.04.2014 171 41 1543 13.04
30.04.2014 169 39 1900 13.2
Total 1223 221 11235 69.58
Date Line Chl Qty Val
15.04.2014 50 10 973 4.56
16.04.2014 144 23 1877 13.31
18.04.2014 167 31 1994 10.69
21.04.2014 162 21 1818 11.92
30.04.2014 104 21 698 3.78
Total 627 106 7360 44.26
AVG : 156
AVG : 125
Packer Name : Mr. Manju Packer Name : Mr. Harish

Date CH Line Qty Value
Time
taken
Tkt Diff
5/5 16 197 1426 876409.02 6:27 200 3
5/6 26 218 1853 1000759.03 4:36 200 -18
5/7 23 211 1248 640487.61 4:51 200 -11
5/8 22 161 2592 925217.71 5:39 200 39
5/9 12 131 2087 1606866.34 5:10 200 69
5/10 28 134 2041 1323214.1 6:42 200 66
5/12 23 156 3366 1042307.81 5:35 200 44
5/13 34 209 1764 926398.53 4:31 200 -9
5/14 34 203 1695 1192973.18 4:58 200 -3
Date CH Line Qty Value
Time
taken
Tkt Diff
5/5 19 189 1113 515109.81 4:09 200 11
5/6 29 180 1488 758204.29 4:32 200 20
5/7 26 197 1078 786213.86 3:19 200 3
5/8 26 172 3809 1215997.17 6:42 200 28
5/9 13 167 1845 883376.79 5:40 200 33
5/10 22 114 693 528700.31 3:19 200 86
5/12 29 204 1147 616593.24 6:40 200 -4
5/13 31 202 1271 844067.25 5:37 200 -2
5/14 38 234 2728 1157857.23 6:38 200 -34
Date CHLine Qty Value
Time
taken
Tkt Diff
5/6 31 193 1144 680389.26 5:07 200 7
5/7 31 203 1008 682592.44 4:13 200 -3
5/8 23 160 3465 1400349.79 5:23 200 40
5/10 27 207 1094 688901.07 5:25 200 -7
5/12 34 189 1473 894294.49 4:40 200 11
5/13 30 204 1595 1011110.76 5:40 200 -4
5/14 31 215 2049 1418591.98 6:33 200 -15
5/15 33 245 1973 987764.24 6:57 250 5
AVG : 184
AVG : 180
AVG : 196
Picker Name : Mr. Chandrasekar
Trail proof

Result :
Based on analyses average picking time for one manpower is 5.5Hrs.
In this 5.5 Hrs Average productivity line is 185.
Claim has been reduced by 70% due to this implementation.
S. No Improvement Old New %
1 Productivity 145 185 20
2 Claim 10 3 70