Moving from Warehouse to Distribution Center Cross Docking

1. Moving from Warehouse to Distribution Center Cross Docking

2. Todd Brandt Unit Head - Logistics Warehousing Tom Stewart Finance Manager Materials Management Financial Analysis Mayo Clinic Rochester, MN

3. Agenda • Mayo Clinic Background • Warehouse vs. Distribution Center • Need for Change • Road to Success • Value

4. Mayo’s Mission • Mayo will provide the best care to every patient every day through integrated clinical practice, education, and research. • Primary Value • The needs of a patient come first.

5. Mayo Clinic Mayo Clinic Scottsdale, AZ Mayo Clinic Rochester, MN Mayo Clinic Jacksonville, FL St. Luke’s Hospital Rochester Methodist Hospital Mayo Clinic Hospital Charter House Saint Marys Hospital Mayo Health System* * A network of clinics and hospitals in 64 communities in southern Minnesota, northern Iowa, and western Wisconsin

6. Mayo Clinic Rochester 28,080 Employees* 322,772 Unique Patients* 1,951 Licensed Beds* 77 Buildings $633M of Supply Spend *as of 9/06

9. Mayo Distribution Center • 60,000 sq ft with 24 ft Ceilings • 5,000 sq ft Mezzanine • 4,000 sq ft Controlled Environment Area • 8,000 Lines / day Ordered • > 50% low unit measure lines • 700 Customer Requisitions Daily • 400 – 500 Receiving Lines Daily • Average Tenure = 16 Years

10. What is a Warehouse? • Warehouse • Storage • Minimize expense • Fill it up! • Few metrics

11. Past- The 90’s • Product Migration • Inventory • Low visibility • Few policies and procedures • No stocking criteria • Traditional Approach • Fill it up!

12. Measurements

14. Past- New Millennium • Product Stabilization • Inventory • Increased visibility • Develop policies and procedures • Unofficial stocking criteria • Guarded Approach • Limited space available

15. Measurements

16. Need for Change • Customer Needs • Just in time • Low unit of measure • Growth • Space utilization • Financial Viability • Change patient demographics • Improving cost structure

17. What is a Distribution Center? • Distribution Center • Organized process • Customer focused • Unique demands • Visible metrics • Cross docking • Consolidation area

18. Road to success • Assemble Team • Create Strategy Map • Determine Baseline • Implement Plan • Measure Progress • Have Some FUN!

19. Assembled Team • Leadership Sponsor • Analytical Staff • Line Staff • Supervisors • Systems Support • Consultant

20. Strategy Map • Current State • Future State • Road Map

21. Slow Moving Parts • Defined Slow Moving • Identify Items • Criteria • Communicate • Disposition • Monitor

22. Velocity and ABC Codes • What is Needed • Create Legend • Slotting • Correct Size • Label SKUs • Reporting

23. Velocity and ABC Codes

24. “A” Velocity SKUs Current Locations 631 “A” SKUs 29 Pick Aisles 2 Floors 427 Over-Stock Locations

25. Order Management and Staff Optimization • Current Patterns • Institution Needs • Customer Needs • Who Controls? • Change

26. Technology • Enterprise Resource Planning • Point of Use • Warehouse Management • Lot tracking • Expiration tracking • Electronic transactions • Staff productivity

27. Standard Operating Procedures (SOP’s) • Requires Process Changes • Inventory control • Slotting • Receiving • Picking • Cycle counting • Communication Tool • Change Behaviors

28. Distribution Processing* • Customers Needs • Lean Process • Save Space • Reduced Inventor * Internal or External

29. Cross Docking • Consolidation • Non-stocks • Delivery Times • Reduce trips • Space

30. Current State • Stock to Non-stock • Inventory • High visibility • Turns • Implement SOP’s • Official stocking criteria • Lean Approach • Low unit of measure

31. “A” Velocity SKUs New Locations 631 “A” SKUs 10 Pick Aisles Ground Floor 211 Over-Stock Locations

32. Product Slotting

33. Measurements

34. Value • Customer Satisfaction • Right product • Right place • Right time • Growth • Optimize space needed for growth • Financial Viability • Optimize Staffing • Improved inventory turnover • Inventory reductions

35. 9.5% C O S 8.0% T 6.5% T O 5.0% S E R 3.5% V E 2.0% SCHEDULED NEXT DAY LOW UNIT DEL LOW UNIT TO UNLIMITED 98%+ FILL CROSS + + BULK DEL. 3 + BULK DEL.. 5 + TO PAR LOC 5 + PAR LOC. 7 + STAT ORDER RATE DOCKING DAYS/ WK DAYS/ WK DAYS/WK DAYS/WK DEL COMMITMENT SERVICES SERVICE OFFERING Cost to Serve Benchmarks *Data provided by National Medical Logistics

36. Future State • Laboratory Expansion • Lot track • Temperature sensitive • Clinical Growth • Space constraints • Flexibility

37. Best Practices • Key Performance Indicators • Documented SOPs • Point-of-use Replenishment Process • Scheduled Pick Waves • Scheduled Deliveries • Velocity Slotting

38. Summary • Evolution • Traditional warehouse • Distribution model • Customer • Flexibility • Value • Lower cost • Quality

39. Q & A brandt.todd@mayo.edu stewart.thomas@mayo.edu