SPRING 2024

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148 THE DISTRIBUTOR’S LINK ROBERT FOOTLIK TWICE THE OUTPUT FROM HALF THE WORKERS from page 108 With a limited number of SKU’s, a simple multi-aisle plan works best. The fewer the aisles, the less walking. Keeping things simple, one aisle with 50 palletized SKU’s for large quantities of fast moving items and a few sections of pallet rack in the second aisle for hand stacked small quantities with pallets below sets up a circular flow path; going up one aisle and returning to a home position without backtracking. If more items must be accommodated, adding pairs of aisles will similarly reduce walking. In a more permanent operation carton flow racks for slow moving, limited SKU’s will consolidate the frontal positions to expedite picking. A maximum aisle length of 50’ to 100’ without a break is normally recommended. If historical data is available, even a pop-up can segregate the most popular items that will appear on the bulk of the orders into one high-speed pick aisle. The very nature of a short term, limited fulfillment program means that the 80/20 rule (80% of the picks come from 20% of the SKU’s) is skewed drastically. As much as 95% of the picks coming from 5% is common. Stocking the layout to take advantage of this is definitely an IOTTMCO preplanning step. “Paperwork” The workers were using real-time bar code scanners tied into a sophisticated warehouse management system (WMS). Every pick required them to scan a floor position label, the product case label and the actual item label to verify location, product and lot codes. This information is download in real time to the WMS for tracking the materials. The problem was that the pickers used the scanners just like a paper list. Materials were profiled in item number sequence, not according to demand, and the orders were being picked individually. One order, one person, at one time is an ancient technique and absurd in an environment where the WMS can be used to direct the work for batch picking of multiple orders. As a pop-up the very limited SKU count and predominantly short (less than three lines) orders are ripe for picking in batches of up to 100 orders at a time, especially if these are all one-line orders. IOTTMCO if the pickers are only getting one item per order pick-pack is a natural and simple procedure. For control purposes, a label printer to supply the carton shipping information (with a suitable bar code) becomes a guarantee that the right goods are going into the right shipping carton, envelope or case lot every time. In essence, the only “paperwork” generated might be a packing list or customized customer communication that an “order finisher” will print as they cushion the carton contents in preparation for carton sealing. This implies that pop-bottom shipping cartons and other supplies travel with the pick-packers who can choose the right shipping medium (or it can be dictated by their handheld WMS link) and place the materials in the carton without wasted time and motion. It may take a few more seconds per order, but pick-pack saves minutes wasted by a packer. Strategically locating packing supplies along the picking path can facilitate resupplying the workers and further reduce their daily travels. This too should be an obvious improvement. Order Checking Under the current operating procedures, multiple “order checkers” are reviewing every item that is going into every box. IOTTMCO they are duplicating inefficiently all the information and verifications performed by the WMS. This raises the question, “Why are they there?” The only answer given attributed this function to “tradition.” A more sensible approach is statistically sampling perhaps 4% of the orders by cutting open finished cartons and evaluating the entire contents the same way a diligent customer would unpack their order. There are many advantages to doing this. This final quality check is an opportunity to assure the customer of your sincerity by including a card or message that the order has been thoroughly checked. Beyond this are the benefits of providing timely feedback to the workers, ensuring that a corrupt employee is not over shipping to a confederate and stopping work immediately when a problem is discovered. If an error is detected, additional sampling must be performed. CONTINUED ON PAGE 149
THE DISTRIBUTOR’S LINK 149 ROBERT FOOTLIK TWICE THE OUTPUT FROM HALF THE WORKERS from page 148 Monetary or incentive rewards provided when goals are met, and exceeded, are based on the final, statistical sampling information. The philosophy is that you are communicating the satisfaction of your customers. Restocking Every time the current pick line was restocked, the pickers had to stop what they were doing and move to safety. Operating a forklift in close proximity to personnel is always an accident waiting to happen. IOTTMCO restocking can be performed during break periods, or by staggering starting times. The cost is essentially zero and no one has to pause. Using the WMS to digitally determine the daily pick quantities expedites the process and should totally eliminate stock outs. If the morning batch of orders includes 52 widgets, then the picking position must have at least this much available at the start of the batch picking period. For a pop-up where multiple pallets of widgets are required, two side-by-side positions can be utilized, or the widgets stocked multiple pallets deep and restocked from a non-picking aisle. Restocking can even be expedited by laying conveyor on the floor to create a movable surface for pallet flow without a forklift. If All This Works For A Pop-Up Operation IOTTMCO, it also works for any Fastener Distributor who has a relatively fast moving operation. Optimizing every order fulfillment process and raising productivity adds profits. Once you develop the right Engineering Attitude, identifying savings of time, money, labor and aggravation becomes a way of life. This is Immediately Obvious To The Most Casual Observer. ROBERT FOOTLIK
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In the Spring 2024 issue of 6 DISTR
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6 THE DISTRIBUTOR’S LINK E&T Fast
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10 THE DISTRIBUTOR’S LINK Eric Du
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14 THE DISTRIBUTOR’S LINK Rob LaP
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28 THE DISTRIBUTOR’S LINK Bruno M
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32 THE DISTRIBUTOR’S LINK Jo Morr
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36 THE DISTRIBUTOR’S LINK INDUSTR
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40 THE DISTRIBUTOR’S LINK Larry B
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44 THE DISTRIBUTOR’S LINK Jim Tru
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The Pacific-West Fastener Associati
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THE DISTRIBUTOR’S LINK 49
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THE DISTRIBUTOR’S LINK 51 SPIROL
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THE DISTRIBUTOR’S LINK 53 The Fas
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THE DISTRIBUTOR’S LINK 55 ISSCO C
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THE DISTRIBUTOR’S LINK 57 Through
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60 THE DISTRIBUTOR’S LINK FASTENE
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64 THE DISTRIBUTOR’S LINK DENALI
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66 THE DISTRIBUTOR’S LINK E-Z LOK
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Star Stainless, a leading wholesale
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72 THE DISTRIBUTOR’S LINK EMAIL i
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THE DISTRIBUTOR’S LINK 75 PREMIER
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THE DISTRIBUTOR’S LINK 77 VOLT IN
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BARBAROTTO INT’L MACHINERY THE DI
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MWFA ANNUAL HOLIDAY PARTY ADDISON,
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PAC-WEST HOLIDAY PARTY & TOYS FOR T
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THE DISTRIBUTOR’S LINK 95 GUY AVE
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Page 101 and 102: THE DISTRIBUTOR’S LINK 99 Endries
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Page 106 and 107: 104 THE DISTRIBUTOR’S LINK CHRIS
Page 108 and 109: 106 THE DISTRIBUTOR’S LINK LARRY
Page 110 and 111: 108 THE DISTRIBUTOR’S LINK ROBERT
Page 114 and 115: 112 THE DISTRIBUTOR’S LINK JIM TR
Page 116 and 117: 114 THE DISTRIBUTOR’S LINK JOE DY
Page 118 and 119: MWFA PUTT SHACK EVENT OAKBROOK, IL
Page 120: 118 THE DISTRIBUTOR’S LINK NELSON
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Page 126 and 127: 124 THE DISTRIBUTOR’S LINK GLOBAL
Page 128 and 129: 126 THE DISTRIBUTOR’S LINK LAUREN
Page 130 and 131: 128 THE DISTRIBUTOR’S LINK ERIC D
Page 132 and 133: 130 THE DISTRIBUTOR’S LINK FASTEN
Page 134 and 135: 132 THE DISTRIBUTOR’S LINK ROB La
Page 136 and 137: fastenerlinks THE DEFINITIVE WEB DI
Page 138 and 139: fastenerlinks BRINGING YOU THE FAST
Page 140: fastenerlinks BRINGING YOU THE FAST
Page 143 and 144: THE DISTRIBUTOR’S LINK 141 YOUNG
Page 145 and 146: PAC-WEST HOLIDAY PARTY & TOYS FOR T
Page 147 and 148: THE DISTRIBUTOR’S LINK 145 CHRIS
Page 152: 150 THE DISTRIBUTOR’S LINK NELSON
Page 155 and 156: THE DISTRIBUTOR’S LINK 153 SPIROL
Page 157 and 158: THE DISTRIBUTOR’S LINK 155 METROP
Page 160 and 161: 158 THE DISTRIBUTOR’S LINK ROB La
Page 162: 160 THE DISTRIBUTOR’S LINK BRUNO
Page 165 and 166: AFC Industries has acquired West Ch
Page 167 and 168: THE DISTRIBUTOR’S LINK 165 BRUNO
Page 170: 168 THE DISTRIBUTOR’S LINK Joe Sh
Page 174: advertisers index E E & T FASTENERS
Page 178: advertisers index R ROTOR CLIP 31 T
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SPRING 2024

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