TTI Improves its warehouse, makes gains...

Page two

The results

Totes have been eliminated from the company's picking operations. The core of the solution involved a system that helped TTI level its processes. TTI was able to progress at a more appropriate pace, despite relentless growth. "Mechanization improves quality and customer service," said Pfretzschner. "If you compare us to some of the other distribution houses, you see conveyors you have to walk over or around on their floors. Other than in shipping, our entire conveyor system is elevated. Consultants suggested that we run conveyors on the floor, and segment the plant."

"Those were the same consultants who told us we couldn't do this without totes," added Beasley.

The system had an instant impact in terms of productivity. "The very first day, we saw a 20% productivity increase," Beasley commented. "Today we've seen an increase of 30%. And I can't calculate how many additional people it would have taken to move the number of totes we would have needed to handle our current growth." Despite the rapidly increasing levels of business, TTI has managed to design an operation that let it do more in what appears to be a more orderly manner. The reality is that more is being done than ever before.

"Visitors are amazed at how quiet and orderly our warehouse is," Golden said. "The facts are the company has grown 125% during this time and our staffing has only grown 20%. We have also seen a dramatic improvement in our quality and a significant reduction in our cycle times."

"We take orders until 7:00 in the evening and ship it the same night to the West Coast to support those customers," said Beasley. "In the past, you might pick an order, and put the tote out, but it might not get picked up for thirty minutes." Now, the picker puts orders on the conveyor, and it is instantly headed to shipping. Delivery times were as much as an hour. Now, delivery of a picked order is four minutes. TTI estimates that it's saved a minimum of 50% on travel time for orders.

Beasley commented, "I must say the implementation of our new conveyor and lift table system has surpassed all of my expectations. Not only did we achieve the obvious improvements, but also it's had a profound impact on our customer service and quality. Without exception our customer feed back has recognized our warehouse and operational capability as being Industry Best."

TTI saw benefits throughout the operation, not just on the processing end. The flow of product improved with single item picking, which allowed elimination of people needed to take totes from one end of the building to the other. The improved flow of the product improved performance in the consolidation and shipping areas.

A high priority was to be able to convey fragile components without damaging them. Because of the way the system handles large and small items together, there is virtually no product damage.

"There have been two keys in our relationship with Cisco-Eagle," Beasley said. "One was that when we came up with ideas, Cisco-Eagle would make them work. Every time we came up with a concept, Cisco-Eagle's response was "let us see what we can do," and that was important to us. The other was the flexibility of understanding our business, and fitting into our daily business.

"We have to give credit to the installation and engineering personnel. You expect this kind of an attitude from a company's sales group. Both site managers we had in here were responsible. They were just as sensitive about working under the conditions we laid down as the management."

"The care and the respect for our equipment, and the care and respect for our facility as a whole was significant," Pfretzschner added. "The installation crews did everything to make sure the site was clean, and that it was safe, and that they worked with our people."

"We've increased quality and productivity," said Beasley. "We have a better work environment. We improved the things like efficiency, and the quality of our work life. We simplified our process and improved every aspect of the operation."

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