• There was a large backlog on materials being left on the receiving area and not visible in the system. This caused issues with material availability and potential lost sales.

Before

Cycle Time = 20.7Days

• Process mapped the workflow and created flow charts.
• Identified major bottlenecks
• Identified communication issues.
• Eliminated not value added activities (i.e. box level vs. part level.
• Changed shifts (Better access to equipment & shelves)
• Changed resource allocation (dedicated team)

• We were able to reduce cycle time by 40%.
• Materials were put on the system 8 days faster on average.

This while number and size of the RCF were increasing.

After

Cycle Time = 9 Days