In 2023, we faced a challenge of low productivity in certain warehouse processes. To tackle this, we embarked on an ambitious Kaizen project aimed at optimizing the electronic tagging process by an impressive 20%. Our starting point was a productivity rate of 240 electronic tags per hour per person.
Our approach was swift and efficient. We applied Kaizen and Lean tools in just four days, starting from kick-off to implementation. The key to our success lay in identifying opportunities through operational walkthroughs. Embracing the principle of "Gemba" (going to the actual place), our team rapidly compiled a list of 38 potential improvement projects.
The transformation took shape on days three and four, marked by key actions such as setting up tables with ANDON signals for skaters and restocking, establishing a STANDARD for wrapping, enhancing process communication, and more.
The result was nothing short of remarkable: a stunning 35% increase in productivity! Key lessons included the realization that "without a standard, there is no Kaizen," and the importance of ongoing training and supervision. This case study exemplifies our commitment to continuous improvement and our innovative approach to overcoming operational challenges in warehouse management.
