Reduction of Waste in Process Flow and Implementation of Value-Added Process

Abstract

The purpose of this project was to improve the process flow of the role of a dock attributor through the elimination of waste, reduction of rework, increasing productivity, and improving the flow of the process at the Evansville TJX Companies Inc. Distribution Center. This general objective is achieved through the application of lean manufacturing techniques and principles and through the integration of improved communication and reduced travel time. The role of a dock attributor is assigned daily to a general warehouse associate in the layup department of the distribution center, who is responsible for correcting all attributing errors during their shift. To design an improved process, it was necessary to: observe the functions of the operation, create current and future state process maps and flow path and layout configurations, gather data for time spent on incorrect attributes, and lastly conduct a 5 why analysis to get to the root cause. Activities such as unnecessary motion and waiting were eliminated, thus contributing to better ergonomics and an increase in productivity. Additionally, through the improvement of the communication and the attributing process; the role of the dock attributor will be repurposed from non-value added to value-added. Furthermore, which would allow for the dock attributor to have a split job function daily, which would increase productivity in the layup department by 34%.