Beruflich Dokumente
Kultur Dokumente
Objectives At the end of this module, the successful student will be able to:
Define JIT
Discuss the benefits of JIT
Discuss the process of order picking
Discuss the packaging of service parts
Explain the application of reusable packaging
Discuss the effect of JIT on packaging requirements
Describe several type of reusable packaging
Discuss the processing of orders in a service parts operation
Define the term "hauling air"
Define the term SKU
Define the terms DC and RDC
Automotive packaging
Automotive or automobile packaging is essentially a misnomer. Few
automobiles are packaged. Instead, automotive packaging is concerned with
products and packages following two distinct paths
When Japanese cars began to sell well in the United States, in the 1970's,
the US manufacturers experienced loss of market share and reduced income
and profit. After much public and private discussion, it was recognized that large
numbers of US customers were purchasing foreign cars because the vehicles
were more reliable and had better overall quality. Workmanship was better and
the cars had fewer defects. There was also a perception of better value for the
money.
Reusable packaging
Most of the automobile companies have initiated reusable packaging
programs. The approaches differ in details, but are generally similar, as
described in the following section.
Containers are designed or selected by and owned by the company, not
the supplier. A number of containers are then provided to each supplier for use
when shipping parts to the assembly
plant. After a shipment has been
received and the parts have been
removed from the container, the
container is cleaned, repaired if
necessary and shipped back to the
supplier or to another supplier using
the same style of container. Dunnage
(the material used to separate
individual items or to fill voids in the
container load) is sometimes reusable
or it might be discarded or recycled after use. If it is to be reused, it must either
be handled separately or the same container must be returned to the original
supplier.
The system, as described, operates like a "pallet pool" in some respects,
but commercial pallet pool operators are not usually involved unless the
assembly plant company has contracted with them to conduct certain activities,
such as supplying the containers initially, container maintenance, cleaning, etc. In
most cases, the reusable system is operated by the company that operates the
assembly plant.
To the extent possible, the companies have tried to standardize the
containers used by various suppliers. A popular style, made of foamed plastic is
used for a wide variety of parts provided by several manufacturers.
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Comment
Shipping empty containers is an illustration of a common problem,
often referred to as "hauling air". A truck filled with empty containers has
no economically valued product, it is essentially carrying "a load of air".
However, the costs of fuel, licenses, tolls, wages for the driver, equipment
repairs, insurance, etc. must still be paid. So it reduces the cost per unit
when additional units can be loaded onto the truck. The common foamed
plastic reusable containers are about 40 inches tall and can be folded down
to a height of about 10 inches. So, four units can be fitted into the space
that would otherwise be required for a single unit.
Other examples of products that cause hauling air include:
Pipe insulation for steam plants, many chemical processes, and even
home use
Spiral wound paper tubes for products ranging from toilet paper to
the large forms used for concrete pillars under highway bridges
Metal cans and plastic bottles moving from the manufacturer to the
filling plant
The amount that can be loaded on a truck can be limited in two ways,
by filling up the volume of the truck, called cubing out, or by reaching the
weight limit of the truck. Hauling air means that the load on the truck has
cubed out - been limited by the available volume of the truck. There are
legal limits (length, height, width) that determine the allowable volume of a
truck. Similar legal limits apply to the allowable weight of a loaded truck.
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There are numerous other types of reusable containers. Several types are
listed below and/or shown in the photos.
Click the green star for an optional, but suggested paper on the topic of
reusable plastic containers
http://www.plasticsresource.com/reading_room/articles/reusable_plastic_contain
ers.html
After some experience was gained, it was recognized that reusable
containers were not an economical approach in all cases. There is, obviously, a
cost involved in returning the containers to the suppliers. Experience has shown
that reusable containers are not generally economical to use if the transport
distance is greater than 400 to 450 miles.
An example of this limitation was shown by the experience at a GM assembly
plant in Marrietta, GA. The plant, which assembled primarily full sized
Chevrolets, received pallet loads of radios, stereos, and similar equipment from a
supplier in Japan. The packaging was well made EPS boxes which provided
containment and protection. Management had directed that the boxes be saved
in a "back room", hoping to find a second use. However, it was simply not
economical to ship empty EPS boxes back to Japan. Eventually, the boxes were
transported to a polystyrene recycling company where they were turned into
other products
are packaged at the DC, before being placed onto storage, if personnel,
equipment, and supplies are available.
Most orders are received from dealers or from the smaller RDC's. The
daily orders are received at the DC and amalgamated into a combined list of
items to be shipped. The computer sorts the list and prepares a work schedule,
taking into account the number of each part that is available, type of packaging to
be used, the amount of each type of packaging that is available, availability of
workers and machines, and similar factors. So, the daily schedule includes all of
the requests for each SKU. The amalgamated list is given to personnel called
order pickers. Using information from the computer, the order pickers find the
location of the SKUs and remove the items that have been ordered. In most
cases, there will be several screws, bolts, gaskets, or other items included in the
order in addition to the basic SKU that was ordered. The stock picker also
assembles the necessary boxes, tape, labels, and other packaging supplies
required to process the order. These materials and supplies are located in a
queue at the entrance to the packaging area.
The packaging crew then picks up the order. The packages are
assembled, the parts are loaded, and the packages are closed and labeled. The
packaging may be done by hand or machine. Completed packages are handled
in two ways. Many small orders are shipped by small package delivery
companies, such as UPS. Items for larger orders are palletized or placed into
large boxes for handling by truck.
For many years, a specific package was specified for each part. However,
it was found that many packages were essentially identical. This system was
very inefficient because supplies of each package had to be maintained. As
increased computer power was made available, it was possible to reduce the
number of packaging SKU's by using one package for several items. Also, JIT is
used for packaging in the same manner as for parts at the assembly plants.
These steps have greatly improved the quality and timeliness of service and
reduced the costs involved in the service parts operations.