Visual Directed Palletizing – VDP^TM

VDP is a solution to the Beverage Distribution problem described in this case study. The product provides a low cost solution with a ROI of 6 months or less. The short ROI is due to the system providing cost reductions in various manual labor processes.

VDP Cost Reduction Areas:

• Eliminates all paper, ink, and printer costs
• Minimizes errors incurred by paper based processes (i.e., keeping track of items on pick list, product identification from SKU or cryptic product description, etc.) And a paper based system cannot provide stacking instructions which then offloads palletizing logic onto operators experience.
• New Operator Training Costs-No ‘shadowing’ of new operator by experienced operator required. VDP is a standalone trainer for new operators.
• New Operator Inefficiency Costs-New operators are immediately productive since there is no training period or learning period.
• Reduced Delivery Errors Savings-Delivery errors are caused by operator picking the wrong product or product quantity. VDP paces operators and provide visual image of product to minimize picking errors.
• Production Planning-supervisor spends a great deal of time planning the production and distributing the work evenly between the available operators. VDP eliminates these tasks.
• Productivity Tracking-supervisors need to track work allocated to each operator for compensation and performance reviews. VDP dynamically tracks work performed by each operator.
• Productivity Management Reports-supervisor generates management reports for operator productivity and total production errors. VDP automatically generates reports based on internal productivity data.
• Elimination of Checker Positions-the system provides a error minimized facility by visually indicating to the operator all relevant information. There is no training or operator experience dependent operations. The system eliminates all errors caused by increasing SKU count, product identification, pallet stacking, layer pattern rules, and quantity mistakes.
• Layer Pick Identification-Increased usage of layer picker, reduction of manual pick. Instead of a fixed set of layer pick products defined as a result of complexities in managing the process, the system can dynamically determine the best set of products to stage for the layer picking process. Since the system coordinates all of the layer picking operations there is no additional burden imposed by varying the products to match the daily production variations.
• Layer Pick Sequencing-As a consequence of being able to determine and manage the pallets that will be assembled through the layer pick process, the system has the ability to determine the best sequence of pallet building for the layer picking operation. This results in minimizing the total amount of work required for replenishment and product movement around the layer pick stations.
• Automated Layer Pick Replenishment-the system provides automated product replenishment for the layer pick operation. Since the system is directing the sequencing of the pallets to be built by the layer picker vehicle, the system will pre-fetch the required products in order that they are available to the operator before they are required for picking. This minimizes the total time required for the layer picking operation.
• Inventory Management-inventory management can be incorporated into the normal pick process thereby eliminating or reducing the effort required by dedicated personnel to track product inventory.
• Automated OOS Resolution – normal out-of-stock conditions are handled through the generation of additional paper forms to reconcile the out of stock item for the customer order. The system provides an automated process which can generate electronic forms to reconcile the customer order.
• Automated HotShot (‘Last Minute’)Orders-Paper based orders can be automated and therefore reducing cost and automating order reconciliation.
• Minimized Pallet Staging Requirement-assembly and staging of pallets are controlled by system and sequenced according to route delivery sequence. This minimizes the area required for staging.

Productivity Enhancements:

• System Directs operator actions so operator’s attention is controlled by system.
• System tracks pick rate for operator.
• System can display productivity goal or peer productivity.
• System displays pick rate to operator to promote self-tracking of productivity.
• System displays next product to pick to operator so operator does not have to fumble with pick ticket paper.
• System displays position AND orientation of product to operator so operator is not burdened with having to memorize product SKU, stacking rules, or layer pattern information.
• System displays to operator the location of the next product to pick so operator does not have to memorize or keep track of where products are stored in the warehouse.

VDP Product Features: