A3 KAIZEN ACTIVITY REPORT

Project Title: Improve productivity at the picking process from direct logistics.
Section / Area : Basauri - Forum Supervisor: Aitor Domínguez Team Name: FORMULA 1 Start Date: OCTOBER 2012
Project Identification : (How did your Team identify this project?) Team : (Core & Support)
This project was identified by the Contract Manager, the Operations Manager and the supervisors after the Iratxe Saez (Contract Manager) (Support)
analysis of the internal kpi.
Hanot Echevarria (Operations Manager) (Suppo

Rationale : (Why should this project be addressed?) Diego Garcia (Capataz) (Core)
Improve productivity so we are able to use more resources at reverse logistcs avoiding Aitor Dominguez (Capataz) (Core)
labour extra cost hiring temporary workers. Jon Andoni Eguinoa (Mozo almacen) (Core)
Javier Garcia (Mozo almacen) (Core)

Guillermo Borregon (Administrativo) (Core)

Current situation : Main Problem : (What is the problem?)

What are the Standard or Target Requirements : (Customer, Site or Business?) The transportation waste represents 3
Increase the ratio of the picking from direct logistics to 134 Units/ hour picking process
Discrepancy : (How big is the gap?)
Average discrepancy 27 units /hour under our target in August, September, October & November from the
current year 2012

Extent : (How Long has it been happening, What is the Trend?)

P
L
A
N

Cause Analysis : (What did you check?) Root Cause : (Direct Causes?)
Fishbone Diagram (Espina de pez = Ishikawa)

The picking strategy is not

The warehouse distribution is not acco
Man Machine Method the correct (it send to the

The materials for the

Waste of time to
assembling
pickers a double run for
missing parts less movements
work (RF terminals boxes
and trolleys) are not
physical tiredness to go into
in good conditions to The time spent at the
the three differents floors at Note codes
prepare the orders verification of the orders
the WHS for stores

Differents ways
to seal the Prices labels
Waste of space at the mezzanine area
boxes (no
method)
Mistake
ubications Causes of: The
codes transportation waste
represents 35% of the
picking time
The picking strategy system it's not the
Supplier boxes
Pick up
Waste of time, when the
pickers are waiting for
the trolleys at the
double run for missing parts)
documents
Broken pallets second and third floor Waste of space at the
mezzanice locations.
Waste of time to Transport to the
move boxes boxes area
The WHS distribution is not
about areas (high or less
Several persons at movements)
the same aisle (not
remove material
enough space)
(throw away) It's not easy move the
The expedition zones are trolleys from B to C
not mark correctly

Materials Measure & Time Mother Nature

Countermeasures : (How will you fix the problem?) Responsibility Start

Measure the locations at the raks and also at the mezzanine area Aitor Dominguez 10-Dic

Start ABC analysis for the mezzanine area and identify the sections which have high movements Hanot Echevarria 13-Dic
D Checksheet implementation (control checks) for the materials (trolleys, RF, cutters, etc) Diego Garcia 26-Dic
O
Standardize the boxes at the mezzanine area (Check the reception process) Aitor Dominguez 15-Ene

Request to HP do the changes at the system for the picking of the missing parts/ products Hanot Echevarría/ Iratxe Saez 18-Feb

Work Instruction -Is a Change Required?: ¨ NO ¨ YES, Implemented on:

Check Results : (At least 30 Days Data).
Before After

C
H
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C
E
C
K

Action & Follow up : (What else needs to be done to ensure Sustainability?) Responsibility Start

A
C
T

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N ACTIVITY REPORT
logistics.
m Name: FORMULA 1 Start Date: OCTOBER 2012
Team : (Core & Support)
Iratxe Saez (Contract Manager) (Support)

Hanot Echevarria (Operations Manager) (Support)

Diego Garcia (Capataz) (Core)

Aitor Dominguez (Capataz) (Core)
Jon Andoni Eguinoa (Mozo almacen) (Core)
Javier Garcia (Mozo almacen) (Core)

Guillermo Borregon (Administrativo) (Core)

Main Problem : (What is the problem?)

The transportation waste represents 35% (average) of the time for the
picking process

Root Cause : (Direct Causes?)

The warehouse distribution is not according sections which have high or
less movements

Waste of space at the mezzanine area locations

The picking strategy system it's not the correct (send to the pickersdo a
double run for missing parts)

End Status
10-Dic Done

19-Dic Done

26-Dic In process

22-Ene To be done

25-Feb To be done

After

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 End Status

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