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#bhscsummit@bhsolutions
Introduction of
Ed WilliamsVice PresidentBlue Horseshoe Strategy [email protected]
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BHS and Cengage
Over a decade of Past Projects
Independence, KY
Toronto, CA
Andover, UK
Mexico City, MX
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Cengage Learning
https://www.youtube.com/watch?v=Rz4rsh5kyJc
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Doing MORE with LESS : The struggle of ‘right now’ expectations and resource limitations
Suzanne WilsbacherProject Manager Distribution Systems Cengage [email protected]
Tony HayesProject Manager Distribution Systems Cengage [email protected]
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Agenda
Introduction & Video
Get CENGAGED!!
Struggles and Challenges
Opportunities for improvement at Cengage
Attendee Feedback & Discussion
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About Cengage Learning
Offering print and electronic learning services
Higher Ed, Research & Library, K-12
MindTap ® Aplia ™ Distribution Centers in 6
countries– United States– Canada– Mexico– Brazil– Argentina– England
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“Managers today have to do more with less, and get better results from limited resources, more than ever before.” – Brian Tracy, Chairman and CEO of Brian Tracy
International, a leadership and development organization, Full Engagement! Inspire, Motivate, and Bring Out the Best in Your People
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You are about to be CENGAGED!
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Challenges and Obstacles
Doing more with less?
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Resource Limitations
Bodies
Brains
Bucks
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Related Fallout
Customer Satisfaction Innovation Employee
Morale
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Cengage OVERCOMES!
T-BOX Packing and Processing
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Cengage OVERCOMES!
PREVIOUS PROCESS 8 Parcels to a tote per
LogPRO Ship label and pick slip
printed interleaved at plan time in tote groups
During picking, Picker had to find the correct label/invoice combo each time and rubber band product to the combo
NEW PROCESS Totes packed out in LogPRO
based on Volume/Weight/# of Parcels configuration
No invoices or labels printed up front
Using voice picking software, Picker picks straight to tote with nothing to match up
Tote Prep and Picking
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Cengage OVERCOMES!
Tote Prep and Picking Benefits– Less conveyor traffic
• More than 8 shipping parcels per tote when packed by Volume/Weight/# of Parcels
• Less conveyor traffic from increased use of totes
– Less tote prep time-• No more matching up invoices and labels
– No handling of invoices or ship/pick labels at all– Pick slip label completely eliminated
• Only need to put tote label on the tote
– Less pick time-• Picker does not need to match up product with correct
invoice/label combo
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Cengage OVERCOMES!
PREVIOUS PROCESS Tote conveyed to Shipping
Dock Pallet of totes driven to cold
seal machines Two operators package
parcels with manual audit of items and invoice/ship label combo
Gaylord of packages driven back to the dock and onto a truck
NEW PROCESS Totes conveyed directly to T-
BOX packing stations on the dock
Parcels packed using LogPro Parcel Audit
Ship label and invoice printed
Packed parcels taken by conveyor to Gaylord
Gaylord driven onto truck
T-BOX Packaging and Shipping
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Cengage OVERCOMES!
T-BOX Packaging and Shipping Benefits– Less double handling-
• Totes are not stacked and unstacked• Parcels are not driven from the dock and back to the
dock
– Improved accuracy (aka MORE!!!)• Each item in each parcels is scanned or ISBN typed
into Parcel Audit• Invoice is printed only for that parcel• Ship label only printed for that shipping parcel
– Less labor-• 1 T-box packer vs. 2 cold seal machine operators
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Cengage OVERCOMES!
Replenishment to TBOX Packing– Entire case of loose is consumed and packed
into TBOX type box
PREVIOUS PROCESS RPLN cases conveyed to
Picking zones RPLN team performs
“Putaway” of cases Picker picks books from
cases into totes Tote conveyed to dock and
then driven to cold seal machine for packing, etc.
NEW PROCESS RPLN cases conveyed
straight to packing stations LogPro performs “Putaway”
at station on conveyor divert Packer scans RPLN label then
item Ship label and invoice print F-key for next label and
invoice, repeat.
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Cengage OVERCOMES!
Replenishment to TBOX Packing Benefits
– Less double handling• RPLN team does not need to handle case• Picking team does not need to pick item
– Less conveyor congestion • Cases sent to pack stations during low
volume, early morning hours• Items not picked into totes, reducing number
of totes on conveyor
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Cengage OVERCOMES!
Benefit Review Less double handling of RPLN cases, items, and
totes Reduced conveyor congestion Reduced label print Reduced tote prep and pick time Reduced error rate for item and invoice/ship label
miss-match Reduced labor Improved error tracking from Parcel Audit stamp of
User ID
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Cengage OVERCOMES!
T-BOX Processing Stations
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Participation Time!
Share what challenges you face, and what you have done to overcome them!
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Cengage OVERCOMES continues!... Daily Staff meeting Cross training Shift timing changes – offer
more flexible work hours Combine synergies
– Order picking with WO picking
– WO module enhancement Work flow management –
pick plan organization and timing
Learning how to do in house
what we used to send out to vendor– Specialized label printing
Ask HVAC contractor to fix ice machine.
Incentive plans for individual contributors
Recognition – Bravo system Meeting of the minds – like
the Blue Horseshoe Summit!!
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Always remember…
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Thank You
Tony HayesProject Manager Distribution Systems Cengage [email protected]
Suzanne WilsbacherProject Manager Distribution Systems Cengage [email protected]
