Work Instruction Pontiac LOC Version 1.0 WI-B404 Bulk Hi-Lo Picker April, 07

Transcription

1 This section describes the process a Hi-Lo Operator / Picker will go through on a "typical" cycle for Bulk. Equipment: 1. Hi-Lo 2. Pen 3. Marker 4. Clipboard General Guidelines: 1) Seat belts will be used at all times. 2) Follow all lift truck regulations. 3) Perform inspection via Forklift/Tugger Checklist at the start of your shift. 4) If you see spilled, damaged or poor quality material in the warehouse: a) Notify Supervisor to complete Non-Conforming Product Exception report. b) Remove material from work area and place in the Non-conforming Product (NCP) Area. c) Attach a copy of Exception Report onto material. 5) Remove all trash and cardboard. Use the bailer to dispose of cardboard. 6) Any additional duties that need to be completed and/or may be requested by the Supervisor. 7) At the end of each shift park Forklift in designated parking area Bulk route pick process: In order to keep inventory levels current according to dates, ALL material must be retrieved in the following F.I.F.O. (First In First Out) manner. DLOC Type: Multiple Row Flow Through Store/Retrieve Method Parts must be pulled from the Retrieve/Pick side of the DLOC from Left to Right using the first empty row as a starting point. If an empty row is not available, start pulling from the row with the oldest date. Parts must be pulled from the Retrieve/Pick side of the DLOC in a straight line. The oldest date must be pulled form the top of the stack. Single Row Flow Through Single Row Non-Flow Through Bulk Rack Material Parts must be pulled in order of oldest Bulk FIFO Tag (Tags can be identified by color of month and date written onto tag) 1. Bulk Picker receives 2 copies of assigned Pick List (Order) from the printer in the Bulk office. 2. Ensure there is an available empty outbound Bulk Route trailer. If not, notify Supervisor immediately. 3. Receive Driver Safety Sheet from Inbound board and ensure trailer wheels are chocked, dock plate is set & secured and dock door is up before entering the trailer. Visually scan the trailer for damage and cleanliness. Notify the Supervisor of damage immediately. 4. Go to proper DLOC where specific parts required off the Pick Order are stocked or staged. If DLOC is empty, check designated Overflow areas for required material. Page 1 of 5 Printed: 06/21/07

2 If required part is a MIN notate MIN in comment field on Pick sheet along with actual quantity over MIN quantity. Notify a Supervisor immediately after finishing Pick. If required part is a No Stock, note on both copies of Pick Order by using N/S to identify this and notify a Supervisor immediately after finishing Pick If Pick does not fit onto trailer: immediately notify Supervisor to contact GM contact for instruction. Note next trailer on both copies of Pick Order and complete add on sheet for next trailer. Parts left off must be the first priority to load onto the next trailer with add on sheet attached and part add on noted on both copies of Pick Order. In the event parts from next pick due not fit due to add on start process over until all Parts have been delivered. Note: Supervisors conduct daily inventory audits using the Bulk Parts & DLOC Log. These Logs are to be used by Bulk staff as a countermeasure for identifying Bulk DLOC s & part locations, including the Min/Max requirements for each part. 5. Retrieve the requested part from the Pick side of the part location via part number and circle quantity on Pick List. 6. Load material onto designated Bulk Route trailer according to requirements listed on the Pick List. Initial each part number on Pick List verifying correct part number and quantity are loaded onto outbound route. 7. Stack similar containers/racks when possible while distributing weight of material evenly throughout the trailer. 8. At end of Pick, total Pick quantities at bottom of Pick List including add on s and direct ship parts to route and initial twice to show route and audit completion. (See Attachment #2) 9. Once trailer loading is completed, put safety chain up or pull dock door down. Transfer any deviations from Pick List onto Plant Pick List and turn in completed Pick List (with name and trailer number) to Supervisor or material analyst. 10. Notify plant shuttle driver when outbound load is completed by placing Plant Pick Sheet in designated outbound clipboard. (Pick Sheet acts as Driver Safety Sheet for Plant Shuttle Drivers only) Unloading Plant Return Trailers: 1) When unloading a return BULK Route trailer stage empty returnable collapsible containers in designated staging areas for breakdown. a) Unload Supplier Specific Containers to designated Supplier Specific Storage area. b) Containers found with return material are to be handled according to return material tag. 1. If return material is not tagged or tag specifies return material to stock: a. Material is to be moved to return material staging area. b. Log Part details onto return material log c. Prior to end of shift designated dock person returns parts to stock on pick side in accordance with FIFO practices 2. If return material tag specifies anything other than return to stock: a. Log Part details onto return material log b. Notify Supervisor c. Move parts to Non-Conforming Product Area Page 2 of 5 Printed: 06/21/07

3 Use the following steps when you encounter a MIN or No Stock condition. A MIN violation will be identified when the part container quantity falls below the MIN quantity indicated on the pick sheet as the part is being picked. (E.g. If the MIN is 3 and there are 3 containers in the storage area when the Pick List calls for 1, the Pick would leave 2 containers remaining. This would be a MIN violation.) A No Stock condition will be identified if there are not enough parts to fill the requested Pick. MIN Violations: a) When a part falls below the minimum number allowed according to the indicated MIN on the pick sheet, verify the MIN by checking the designated overflow area. b) If there is no material in overflow for specified part request on the Pick List notate MIN in comment field on Pick sheet along with actual quantity over MIN quantity (See attachment #1) c) If there is no material in overflow for specified part notify Supervisor of MIN. No Stock Condition: a) If only a portion of the request was filled, write the number picked and NS next to the part number on both Pick Lists. Circle the actual quantity picked on both Pick Lists. b) The Picker should already be aware of this shortage and notifies the Supervisor that he is out of parts. c) Supervisor verifies the part is not in house by checking overflow areas & receiving docks. d) Supervisor notifies Material Analyst of No Stock. Special Instructions: Loading Batteries: 1. Always load batteries on the rear of the trailer (see photo 1C) 2. Never stack on top of the batteries 3. A hazardous Bill Of Lading must be sent with every plant shuttle containing batteries Shipping Glass Parts 1. Procedures for unloading all Glass Parts: a.) Only use Hi-Lo with 42 forks b.) Only pick-up load from the end of rack (see photo 1b) c.) Always drive Hi-Lo completely flush to rack mast of Hi-Lo must rest against windshield rack. (see photo 1a) d.) Only carry 2 racks stacked together e.) Always raise the rack never push a rack of windshields on the warehouse floor. f.) The speed of the Hi-Lo when moving a rack of windshields is walking speed. g.) Do not jar or drop windshield racks on warehouse floor. h.) Never pick-up windshield racks from the load/unload side of racks (i.e. the side that the operator would remove/install windshields from rack. Page 3 of 5 Printed: 06/21/07

4 Work Instruction WI-B404 Pontiac LOC Bulk Hi-Lo Picker Version 1.0 April, 07 1B-Glass rack must be flush against forklift mast 1A-Pick up glass on the ends only, never the sides 1C-Load batteries on the rear of the trailer only. Engineering Change: If during the Pick process the DLOC and specified part number has an engineering change and the last container of the old part has been picked, the new part must be used in place of the old part (see Supervisor if this occurs) The old part number must be crossed off the Pick and Delivery List with the new part number written in Page 4 of 5 Printed: 06/21/07

5 Contingency Plan: (in event of system failure) If your Pick Lists do not print, you must immediately notify your Supervisor for backup instructions (i.e. reprint pick in EPS system) If you are late in starting your Pick or fall behind in completing your Pick, please notify Supervisor once Pick is completed and notify Stocker for help in order to get back to schedule Page 5 of 5 Printed: 06/21/07

6 I acknowledge that I have read, been trained on, and fully understand the above work instructions and will follow them at all times unless otherwise instructed by my supervisor. Employee Name (Print) Employee Signature Supervisor Signature Date Date Page 6 of 5 Printed: 06/21/07