This project focused on improving the picking phase through the A3 tool in a metallurgical company based in Lombardy. During the meetings with the company, the desire to act on the packaging department was expressed, with the aim of reducing the time of picking and inefficiencies inside the warehouse. Specifically, the target defined by the company was equal to a 15% reduction in inefficiencies regarding the picking activities and also the management of the warehouse. Reduce the inefficiencies meant to act on the time spent by the warehouse operators to process an order during the picking phase. For this reason, direct observations and measurements were conducted in order to state and evaluate the current performances. Through these actions, some non-value-added activities have been discovered that increase the cycle time of the picking phase. Some sessions of brainstorming allowed to define the root causes of the problems. They were discussed and analysed more deeply in order to find countermeasures. The main problems were related to the policies with which the picking activities were managed and the no organization within the warehouse. These problems were faced by introducing a new equipment especially at the warehouse level (new racks, forklift and WMS) and new method/policies for the picking activities. The final solution involves both the picking activities and the warehouse management and being closely related, it is possible to benefit from the new synergies that will be created once fully operational. The implementation of the solution will decrease the total time to do the picking phase, with a consequent reduction of inefficiencies by 67% and with a reduction of resources to complete these activities.
Questo progetto si è concentrato sul miglioramento della fase di picking attraverso lo strumento A3 in un’azienda metalmeccanica Lombarda. Durante gli incontri con l'azienda è stata espressa la volontà di agire sul reparto packaging, con l'obiettivo di ridurre i tempi di picking e le inefficienze all'interno del magazzino. Nello specifico, l'obiettivo definito dall’azienda è stato pari ad una riduzione del 15% delle inefficienze relative alle attività di picking e alla gestione del magazzino. Ridurre le inefficienze significava agire sul tempo speso dagli operatori del magazzino per elaborare un ordine durante la fase di prelievo. Per questo motivo, sono state condotte osservazioni e misurazioni al fine di stabilire e valutare la situazione attuale. Attraverso queste azioni, sono state identificate alcune attività senza valore aggiunto le quali aumentano il tempo di ciclo nella fase di picking. Alcune sessioni di brainstorming hanno permesso di definire le cause alla radice dei problemi. Successivamente queste problematiche sono state discusse e analizzate in maniera più approfondita al fine di trovare soluzioni ottimali. I problemi principali erano legati alle politiche con cui venivano gestite le attività di picking e alla mancanza di una gestione ottimale del magazzino. Questi problemi sono stati affrontati introducendo una nuova apparecchiatura soprattutto lato magazzino (nuovi rack, carrelli elevatori e WMS) e nuovi metodi / politiche per le attività di picking. In conclusione, la soluzione finale coinvolge sia le attività di picking che la gestione del magazzino ed essendo strettamente correlate sarà possibile beneficiare delle nuove sinergie che verranno a crearsi una volta che le soluzioni saranno pienamente operative. L'implementazione della soluzione ridurrà il tempo totale necessario alla fase di picking, con una conseguente riduzione delle inefficienze del 67% e con anche una riduzione di risorse per completare queste attività.
Design of a new warehouse through the A3 tool
ANSELMI, LORENZO
2017/2018
Abstract
This project focused on improving the picking phase through the A3 tool in a metallurgical company based in Lombardy. During the meetings with the company, the desire to act on the packaging department was expressed, with the aim of reducing the time of picking and inefficiencies inside the warehouse. Specifically, the target defined by the company was equal to a 15% reduction in inefficiencies regarding the picking activities and also the management of the warehouse. Reduce the inefficiencies meant to act on the time spent by the warehouse operators to process an order during the picking phase. For this reason, direct observations and measurements were conducted in order to state and evaluate the current performances. Through these actions, some non-value-added activities have been discovered that increase the cycle time of the picking phase. Some sessions of brainstorming allowed to define the root causes of the problems. They were discussed and analysed more deeply in order to find countermeasures. The main problems were related to the policies with which the picking activities were managed and the no organization within the warehouse. These problems were faced by introducing a new equipment especially at the warehouse level (new racks, forklift and WMS) and new method/policies for the picking activities. The final solution involves both the picking activities and the warehouse management and being closely related, it is possible to benefit from the new synergies that will be created once fully operational. The implementation of the solution will decrease the total time to do the picking phase, with a consequent reduction of inefficiencies by 67% and with a reduction of resources to complete these activities.| File | Dimensione | Formato | |
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https://hdl.handle.net/10589/142401