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In a perfect world, there is a relatively straight and logical flow as products are received at a distribution center and later shipped to customers. In fact, however, the supposedly logical flow of material looks more like a bowl of spaghetti. One way to identify improvement opportunities is to compare the actual spaghetti with the ideal flow. What changes might straighten out the pasta-like crooked and wasteful movements?
For example, an ideal inbound flow would start with unloading at a receiving dock, staging until quality inspection is done, then put away to a predetermined storage location. But it doesn’t always work that way, and charting the actual movement versus ideal will identify problems that should be corrected. The same process could then be applied to picking, packing, labeling, and shipping. When it doesn’t actually flow as expected, what is going wrong?
Backtracking or unnecessary travel can be caused by congestion, safety concerns, equipment breakdowns, or unexpected bottlenecks. Inefficient storage layout may be a problem. Inadequate or improperly designed handling equipment could be another. Adjusting staffing levels or shifting schedules may correct the situation where there are not enough hands where they are needed.
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