FINAL PRESENTATION
P10714 -COOPER VISION
Aditya Manjrekar
Industrial and Systems Engineering
KGCOE, RIT.
PROJECT STATUS UPDATE
Project Name
Cooper Vision
Project Number
P10714
Project Family
Lean Production
Track
Process Innovation
Start Term
2009-1 (Fall ) for MSD1
End Term
2009-2 ( Winter) for MSD2
Faculty Guide
John Kaemmerlen (ISE)
Industrial Teaching Adviser
Phil Bryan
Faculty Consultant
Andres Carrano (ISE)
Primary Customer
Sarah Pittman, Process Improvement Manager
WHAT AM I GOING TO TALK ABOUT TODAY
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6)
Re-visit project background and facility.
Planning
Concept Development.
Targeted Specifications.
Team Requirements and Work Breakdown.
Risk Assessment.
ABOUT COOPER VISION
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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 Includeo
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Wal-Mart, Target and similar stores.
Doctors and Pharmacies.
Large scale Distributors like 1800-Contacts.
Patients. ( Biggest Customers – teenagers and youth)
DISTRIBUTION CENTER IN HENRIETTA
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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.
FACILITY LAYOUT
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Bulk Inventory Storage
Packaging Dept.
ADM
Receiving
Pick to Light.
Pick to voice.
Carousel Picking
Shipping
White box labeling
International Orders
Reworking/ Returns.
PLANNING
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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.
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Relevance.
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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.
CONCEPT DEVELOPMENT
List of Issues
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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
ISSUES
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Pick to Light/ Pick to
Voice- Ergonomic
Concerns.
White Box Labelingfor brand customers.
ADM Replenishment
flags.
Reslotting similar
colored items – to
reduce mistakes.
Carousel
Replenishment time.
AFFINITY DIAGRAM
Order picking
Efficiency
•Reduce box
flipping.
•Decrease
double handling
•Increase order
picking
accuracy.
•Picking labels
for white boxes.
•Reduce
reworking and
returns of
mistakes.
Replenishment
•Reslotting by
frequency of
pick.
•Replenishment
signals on ADM.
•Decrease
Carousel
Replenishment
time.
Workforce
Utilization
•Determine daily
requirement to
reduce labor
flexing wave.
•Have work force
utilization close
to 100% and
accommodate
for growth.
•Reduce Pick to
light walk time
and bending.
Software.
•Synchronize the
ERP (Baan) and
WMS (Red
Prairie)
Systems
•Occasional
glitches in Pick
to voice system
OBJECTIVE TREE
FUNCTION TREE
HOUSE OF QUALITY
Improve
Replenishment
Close gap b/w
Software system
and real system
Improve Picking
system
Orders need to be
shipped earlier
3
7
9
We need better
level of customer
satisfaction
3
3
7
Labor needs to be
utilized efficiently
8
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7
The software
matches real needs
3
9
8
VOC to VOE
TARGET SPECIFICATIONS
According to the HOQ and the
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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.
STAFFING REQUIREMENTS
Industrial Engineer- Project Lead
 Industrial Engineer – Systems
Analysis
•Project Management .
•Value Stream Mapping
•Facilities planning
•Lean initiatives for quality
improvements.
•Arena or other Simulation Tools.
•Data Analysis.(Excel solver)
•Optimization tools.
•Ergonomics and Human Factors.
Industrial Engineer- Facilities
Management
 Mechanical Engineer – Mechanical
•Facilities and Warehouse
planning and design.
•Design and Analysis of Production
System
•AutoCAD – Factory CAD
Process Improvement tools.
•Moving high volume objects.
•Expertise at Dynamics.
•Machine Shop Experience.
•Ready to learn more about nonconventional ME tools development.
•AutoCAD and Solid works
WORK BREAKDOWN STRUCTURE.
Person
Week 0->1 Tasks
Week 1->2
Tasks
Week 2->3
Tasks
Team Lead
IE Student 1
Prepare set of Skills to
discuss in first meeting.
Familiarize with previous
project.
Develop Project Pert
chart and schedule.
Meet Customer and
tour Facility.
Brainstorm Top 3-5
Improvement Areas.
Assign work roles.
IE Student 2
Prepare set of Skills to
discuss in first meeting.
Familiarize with previous
project.
Analyze the available
data from WMS of CV to
find spikes. Meet
Customer and tour
Facility.
Brainstorm Top 3-5
Improvement Areas
IE Student 3
Prepare set of Skills to
discuss in first meeting.
Familiarize with previous
project.
Research shelving
methods and picking
techniques in
warehouses.
Brainstorm Top 3-5
Improvement Areas
ME Student
1
Prepare set of Skills to
discuss in first meeting.
Familiarize with previous
project.
Gather information
about high volume
movement of totes,
boxes.
Brainstorm Top 3-5
Improvement Areas
RESOURCE REQUIREMENTS
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
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ERP Software:- Baan
WMS Software:- Red-Prairie.
Budget:- TBD by Customer.
RISKS AND CONTINGENCY PLANS
Description of
Risk
Possible
Consequen
ces
Probability
of Risk
(H/M/L)
Severity
of Risk
(H/M/L)
Overall
Risk
(H/M/L)
Contingency Plan
Higher
Management
Restricts
WMS/ERP
software changes
May not be
able make
the optimal
changes to
software.
H
M
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Do not make changes to
current software , just
remove glitches , add-ons
to existing software. Test
before implementing
Organizational
Right staff
/employee not
available
Right
Information
unavailable
at right time.
M
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Find Alternative
Information source like
another staff member or
historical records.
Purchased Item
does not arrive on
time or is
defective.
Delays the
dependent
plans and
processes.
M
H
M
Restructure the sequence
of actions in the plan to
accommodate this . Order
multiple parts.
One of the team
member does not
have enough work
to do.
Decrease in
Motivation.
Under
utilization of
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Re-assign the team
member to another set of
tasks done by another
member and matches
MEASURES OF SUCCESS
Primary customer satisfaction.- Set Realistic
goals with Customer.
 Improvement in number of picks per hour/day.
 Percentage reduction in the number of rehandling 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.
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INTELLECTUAL PROPERTY CONSIDERATIONS
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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.
SOURCES
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Interviews.
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Attended.
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Sarah Pittman, Process Improvement Manager , CV.
John Kaemmerlen, MSD Faculty Adviser.
MSD ( P09721) Team
Aaron Heyman- Team Lead.
Mid-term Review presentation
Final Review and customer hand-over Meeting
Poster Presentation at Imagine RIT
Web-pages
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Cooper Vision Website ( www.coopervision.com)
Edge Website for Project P09721
(edge.rit.edu//content/P09721/public/Home)
THANK YOU
Questions