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Best Practices for Auditing LTL Orders?

Six Sigma – iSixSigma Forums General Forums General Best Practices for Auditing LTL Orders?

This topic contains 15 replies, has 5 voices, and was last updated by  Joe Wojniak 3 months, 2 weeks ago.

Viewing 16 posts - 1 through 16 (of 16 total)
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  • #237607

    JMiller2019
    Participant

    Anyone have some insight on best practices for auditing LTL orders without breaking down the entire skid to count cases? Our WMS system will mark each item as picked via a scan gun but it is up to the picker to count out the correct amount of cases. Our pickers do not have carton labels for each case either. All cases picked are palletized and a shipper will wrap the skid and mark it as shipped in the WMS. We are having some picking errors where we short ship or over ship our customers. Usually this is due to not pulling the correct amount of cases (ex. order is for 24 pcs total and each case is 3 pcs each. The picker only physically pulls 7 cases instead of the 8 cases needed).

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    #237610

    Mike Carnell
    Participant

    @jmiller2019 Weigh it.

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    #237657

    Mjcol1388
    Participant

    Does your system have the capability to scan each item individually to identify items pick? How many counters are there throughout the process?

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    #237745

    JMiller2019
    Participant

    Our scanners require the pickers to scan the bin, scan the item, but type in the qty being picked. It is up to the picker to pull the correct amount of cases to equal up the amount of pieces on the order. Our IT department is working on an update to the scanners that forces the pickers to scan each box and the inventory is “picked” on the order as each case is scanned.

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    #237762

    Mike Carnell
    Participant

    @jmiller2019 Can I pick it and not put it on the pallet?

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    #238005

    tbillow
    Participant

    We have the exact same problem and picking process you have. We use to tear down the skid and audit it, however could only get to 10% of outgoing product. We have switched to a team auditing approach. We have 7 people that throughout the week will audit the pickers while they are picking and building the skids. This is currently in an experimental stage to see if we can help keep the picking teams accountable.

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    #238011

    Mike Carnell
    Participant

    @tbillow Your solution is to add an inspection step to make sure they did it right? You can Mistake proof this an not need to do that i.e. spend the money. From the pick sheet you should be able to calculate a weight range that is acceptable if it is filled properly. Weigh it when you stage it and weigh it when you pack it. There are scales that will weigh it on the move. Why would you tear it apart?

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    #238028

    tbillow
    Participant

    @mike-carnell we no longer tear it apart. That was the process when I joined the company however it was no value add. I had not thought about weighing the skids. That might be a good idea to try. Thank you.

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    #238030

    Mike Carnell
    Participant

    @tbillow I have no idea how much your product weighs but this is what we have done in the past. Your pick sheet knows what you need to pick to fill an order. If you attach it to a data base that knows how much product will weigh (range) that way you should know How much the order should weigh. You can do a couple things here. Pick the whole list and weigh it but if you are short you will need to figure out what you are short. If you can pick to a scale you will make sure you pick the correct amount. When you are done you know how much the order weighs so if you have to palletize then you weigh the pallet or zero the scale and transfer.

    If you have those self checkout deals at Home Depot it is similar. You can also get weigh bridges/conveyor scales that will weigh on the fly.

    If you can weigh as you pick it will increase your pick accuracy, reduce shrinkage and reduce rework. Management can get a little hyper when you propose buying scales but compared to rework cost and shrinkage it is negligible. I would calculate those numbers just for a baseline for any improvements you do.

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    #238031

    JMiller2019
    Participant

    @mike-carnell Thanks for the insight. I will work with out IT team to see if we can calculate the estimated weight on the picking tickets so the pickers can weigh each package before shipping. I think this will work well for parcel shipments. A single freight order of ours are sometimes up to 40-50 skids so I am not how to break down how much each skid should weigh. We would have a total estimated weight but how would we know how much each skid should weigh?

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    #238036

    Mike Carnell
    Participant

    @jmiller2019 Does your customer have requirements on how to pack a skid? If they don’t then you can create your own (standardized Work). It can help you with consistency and accuracy as well.

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    #238065

    JMiller2019
    Participant

    @mike-carnell No specific customer requirements for palletizing.

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    #238071

    Mike Carnell
    Participant

    @jmiller2019 I would create a document,screen, etc. that specifies how to pack a pallet. Actually you can have your packers help create it. It becomes standard work and if you have a process you are less likely to have them miss something.

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    #238090

    JMiller2019
    Participant

    @mike-carnell thanks for all the help on this. Much appreciated.

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    #238094

    Mike Carnell
    Participant

    @jmiller2019 you are welcome

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    #238858

    Joe Wojniak
    Participant

    These are great ideas, weighing the pallets, using counting scales to weigh small loose bulk items also helps. In addition, determining where in the sequence the miscount occurs can also help (i.e. when is the item or box scanned as picked?)
    1. Scan, pick, load onto pallet -> item may be scanned but not picked, resulting in a missing case.
    2. Pick, scan, load onto pallet -> All picked items are scanned. Hopefully, there is little opportunity for picked items to not be placed on the pallet?
    3. Use a pallet jack to move the pallet to the pick locations (vs. bringing cases to the pallet on the shrink wrapper)
    4. Preventive: ensure pick orders are equivalent to 1/3, 2/3, 3/3 of pallet (if there are 3 layers of cases on the pallet.)

    Problem-solving method: use fish-bone diagram / Ishikawa diagram to brainstorm possible causes of missing cases.

    Validate potential solutions: did the problem get fixed? what fixed it?

    • This reply was modified 3 months, 2 weeks ago by  Joe Wojniak. Reason: add hyperlink to fish-bone diagram explanation
    • This reply was modified 3 months, 2 weeks ago by  Katie Barry.
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