Robust Production Management (RPM) Module 10: Small Warehouse Case Study (PDF)

In this case study of a small warehouse operation, Robust Production Management (RPM) techniques, tools and concepts were applied to identify and quantify the spare capacity and operational savings opportunities present in the organization. If you've studied the previous RPM modules, you'll quickly recognize real-world examples of time studies, the performance framework, resource alignment matrix and unit cost analysis – including 'before and after' states for the organization. "Small Warehouse Case Study" is the tenth module in the Metrilogics Robust Production Management (RPM) training series – more on the way.

This module dives deep into the granular data of individual team member performance, breaking down direct and indirect hours, task volumes, and quality metrics. It provides a comprehensive look at how non-chargeable downtime, lost time in meetings, and direct task work impact overall productivity. The analysis includes detailed charts and graphs that highlight areas of opportunity and spare capacity, making it easier to pinpoint inefficiencies and implement targeted improvements.

The PDF also outlines the methodology for establishing direct task capacity rates, incorporating both hands-on processing time and other business-related activities like task preparation, unavoidable interruptions, and workstation maintenance. This holistic approach ensures that all aspects of warehouse operations are considered, providing a more accurate picture of capacity and performance. The case study's recommendations are backed by robust data, offering actionable insights for redistributing work volume, enhancing skills training, and implementing performance feedback mechanisms.

Key performance indicators are tracked meticulously, with daily receiving putaway units, logistics cycle count locations, and hourly data presented in clear, easy-to-understand formats. The proposed organizational changes, including a streamlined FTE complement and a revised warehouse org chart, aim to optimize resource allocation and improve overall efficiency. This module is an essential resource for executives looking to drive operational excellence in warehouse management.