QUESTION: Develop a high-level process flow chart for the current process

The facility is 250,000 sq. ft, with about 50% dedicated to their outbound operation (picking, packing and shipping). The remaining 50% is dedicated to receiving product and pallet storage.

The client currently is shipping 10,000 orders per day on average. Each order averages 5 units.

The client is running 2 shifts, 7 days a week. Each shift is 10 hrs.

The picking operations is pick to cart, each cart having 25 orders. Picking orders is done using RF guns (scanner) that direct the picker to the location of the product, the quantity to pick, and the order bin on the cart.

The picking area is 75,000 sq. ft of shelving. The shelving is 6 ft high, 8 ft long.

After all orders on the cart have been completed, the carts are delivered to the packing area to inspect and pack out the order into the shipping box. The orders are then conveyed to a truck for loading and delivery.

There are 25 packing stations and it takes up 25,000 sq. ft.

Each packer packs out one cart at a time. The also us an RF gun to scan the order bin. They then scan each item on the order to confirm it was picked. If all items are there, they place them into the correct size order box, weight the order on a scale, print and insert the packing list, and print and apply the shipping label to the box. The order box is then placed on a conveyor to be transported to shipping to be loaded on the appropriate truck.

The current productivity rates are:

Picking: 50 units per hour.

Packing: 100 units per hour.

Labor rates are $15 per hour with a 25% load factor.