The Toyota Way to Service Excellence by Jeffrey K. Liker

Author:Jeffrey K. Liker
Language: eng
Format: epub
Publisher: McGraw-Hill Education
Published: 2017-04-10T04:00:00+00:00

Figure 6.7 Standard work sheet for picking orders at Zingerman’s Mail Order

It might appear rather obvious how to pick items off a shelf and put them in a bin. As you read down through the standard work it is surprising how much is involved in this apparently simple job. This is in part because of the lean systems. There are clear standards for where every item is located with distinct addresses and visual management identification. Consider the “Special Instructions” for non-recurring tasks. There is a kanban system for replenishing items and that needs to be understood. There is a standard for what to do with empty totes and one for dealing with empty dry good totes. In many warehouses all we would know is to look up the item on the pick list and find it, perhaps using some bar code technology. As ZMO developed visual standards, errors in picking were dramatically reduced, and at the same time there was more to teach in the “recipes.” As you transform to lean there will be more detailed standard work and a greater need to do a good job of team member training. Some people say that lean does not work with temporary workers, but in fact, it becomes even more critical.

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