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Final Presentation P10714 -Cooper Vision

Aditya Manjrekar Industrial and Systems Engineering KGCOE, RIT. Final Presentation P10714 -Cooper Vision. Project Status Update. Re-visit project background and facility. Planning Concept Development. Targeted Specifications. Team Requirements and Work Breakdown. Risk Assessment.

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Final Presentation P10714 -Cooper Vision

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  1. Aditya Manjrekar Industrial and Systems Engineering KGCOE, RIT. Final PresentationP10714 -Cooper Vision

  2. Project Status Update

  3. Re-visit project background and facility. Planning Concept Development. Targeted Specifications. Team Requirements and Work Breakdown. Risk Assessment. What am I going to talk About today

  4. Manufacturing prescription contact lenses for five decades • America's second largest maker of prescription contact lenses and #1 maker of toric contact lenses for the correction of astigmatism. • Extensive network of facilities in 12 countries across five continents with it’s headquarters at Fairport, NY . • One of the highest level of on-time order fulfillment in the industry. • Customers Include- • Wal-Mart, Target and similar stores. • Doctors and Pharmacies. • Large scale Distributors like 1800-Contacts. • Patients. ( Biggest Customers – teenagers and youth) About Cooper Vision

  5. 250,000 square feet • The Single major Cooper-vision distribution center in the country. • Very good picking system- • Pick to light • Pick to voice. • ADM-Automated Distribution machine. • Carousel Picking. • Totes, Boxes through conveyers , lifts and bins, • Close to 400 Employees on floor and 100 staff for support. • On hand inventory for any product is never zero. Distribution Center in Henrietta

  6. Bulk Inventory Storage • Packaging Dept. • ADM • Receiving • Pick to Light. • Pick to voice. • Carousel Picking • Shipping • White box labeling • International Orders • Reworking/ Returns. Facility Layout

  7. Mission Statement. :- The team aims to improve existing processes in use at the Cooper vision facility by suggesting lean system changes, software tools and recommending improvements to make the distribution center more efficient and to address the issues faced by the company and its employees. • Relevance. • List of suggested 62 different improvement tasks. • The customer would like to invest time and money in the MSD project to get a quality tools and tangible process improvement ideas. • Some primary needs are worked on by current MSD team and next few tasks need to be completed by future teams. • Some to be completed by Co-op students , full time employees. Planning

  8. List of Issues • Boxes flipping on none label on the conveyer. • Un predictable daily volume of orders. • Therefore a wave of labor flexing from receiving to shipping. • Double handling totes during peak hours. • Too many waste cardboard boxes Concept Development

  9. Pick to Light/ Pick to Voice- Ergonomic Concerns. • White Box Labeling- for brand customers. • ADM Replenishment flags. • Reslotting similar colored items – to reduce mistakes. • Carousel Replenishment time. Issues

  10. Affinity Diagram

  11. Objective Tree

  12. Function Tree

  13. House of Quality

  14. According to the HOQ and the • Probability of success • Severity / Impact to customer. • Urgency according to customer • Cost and time for project. • Concentrate on the following needs. • Reduce rework and double handling. • Reduce walk time and bending. • Reslotting SKUs for efficient picking. • Improve White box label picking. • Synchronize ERP and WMS systems. Target Specifications

  15. Staffing Requirements

  16. Work Breakdown Structure.

  17. Time in the Cooper-Vision Distribution Center. • Access to Staff members and Floor Employees. • Machine Shop Equipment for Mechanical improvements.. • Software Licenses:- Arena , AutoCAD, Excel. • Faculty Expertise ( Kaemmerlen , Carrano) • Trial license or time on • ERP Software:- Baan • WMS Software:- Red-Prairie. • Budget:- TBD by Customer. Resource Requirements

  18. Risks and contingency plans

  19. Primary customer satisfaction.- Set Realistic goals with Customer. • Improvement in number of picks per hour/day. • Percentage reduction in the number of re-handling and rework. • Improvement in job quality of on floor employees. • Improvements are within specifications • Easy to implement by primary users • Completed well within 22 week time frame. Measures of success

  20. All work to be completed by students in this track is expected to be released to the public domain. Students, Faculty, Staff, and other participants in the project will be expected to release rights to their designs, documents, drawings, etc., to the public domain, so that others may freely build upon the results and findings without constraint. • Students, Faculty, and Staff associated with the project are encouraged to publish findings, data, and results openly. Intellectual Property Considerations

  21. Interviews. • Sarah Pittman, Process Improvement Manager , CV. • John Kaemmerlen, MSD Faculty Adviser. • MSD ( P09721) Team • Aaron Heyman- Team Lead. • Attended. • Mid-term Review presentation • Final Review and customer hand-over Meeting • Poster Presentation at Imagine RIT • Web-pages • Cooper Vision Website ( www.coopervision.com) • Edge Website for Project P09721 (edge.rit.edu//content/P09721/public/Home) Sources

  22. Questions Thank You

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