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 ,
Cooper Vision.
About Cooper Vision
 Manufacturing prescription contact lenses
for five decades
 Thousands of leading brand names
 Hydra soft
 Vertex
 Preference
 Frequency
 Avaira
 America's second largest maker of
prescription contact lenses.
 #1 maker of toric contact lenses for the
correction of astigmatism.
Background Information
 The Cooper Companies, Inc. is a specialty health care
company. Its two business units serve niche markets in the
medical device market .
 Cooper Vision (CVI) markets a broad range of contact lenses
throughout the world.
 Cooper Surgical (CSI) markets diagnostic products, surgical
instruments, and accessories for the women's healthcare
market.
 Headquarters at Fairport, NY .
 Extensive network of facilities in 12 countries across five
continents
 One of the highest level of on-time order fulfillment in the
industry.
Distribution Center in Rochester
 Currently they operate a 250,000 square foot distribution
center in Henrietta, NY.
 Very good picking system
 Pick to light
 Pick to voice.
 Automated- Integrated conveyer line.
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Normal Order Picking- 24 Hrs goal.
Bulk Order Picking- 48 Hrs goal.
On hand inventory for any if given product is never zero.
Sarah Pittman, Process Improvement Manager for Cooper
Vision – Alumni of the ISE Department , RIT.
Phase 0: Planning
Mission Statement
Product Description /Project Overview
The facility at Henrietta , is going through process improvement changes to better
order fulfillment time , customer satisfaction and streamline their distribution. Value
added changes need to made to the system through computer tools ,improvements in
facility and equipments and through kaizen events.
Key Business Goals/Project Deliverables The primary business goals of this project are to
Improve Order picking and shipping times.
Improve Workforce utilization due to variable demand levels.
Increase the market share of Cooper vision lenses, by improving customer
satisfaction levels.
Primary Market /Project Opportunities
The primary market for this is the central distribution facility in Henrietta NY.
Secondary Market /Project Opportunities
Secondary markets for this system are the other distribution center around USA and the rest of
the world , that can use similar tools and improvements to better streamline their distribution
and fulfill customer needs.
Stakeholders
Cooper Companies- Cooper Vision (CVI)
Other Stakeholders in the project include the following:
The Final lens user.
The retailer /seller, such as pharmacists and 1800-Contacts.
Doctors ,Practitioners.
The Community in which the facility resides.
Phase 1: Concept Development
Identify Customer Needs - Interviews
Primary Customer(s)
Sarah Pittman and Jim Della Valle of Cooper Vision facility in Henrietta.
Not Interviewed yet.
Sarah Pittman and Jim
Della Valle to be interviewed at the distribution facility during week 6
or 7 in Spring 09.
Indicated to the current project team that there are many more improvement tasks that can
become future MSD projects.
Findings to be captured in the format of a textual document with supporting pictures, charts
and tables.
Other Stakeholder(s)
Secondary Stakeholder is the RIT Senior Design Program
Interviewed Prof John Kaemmerlen (ISE) in Week 5 , spring quarter.
Findings noted in Log Book. Initial knowledge to be entered on Edge .
Past Senior Design Team(s)
 Interviewed Current Multidisciplinary Senior Design team – Winter/Spring 08-09
with Team Lead Aaron Heyman (ISE)
 Current usefulResources to draw upon
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Documentation of previous Interviews and Brainstorming sessions.
Capacity Analysis tool ( Excel based for the Henrietta facility )
white paper that describes in detail the steps taken by the team to complete process
Improvement tasks.
Charts and tables describing their findings.
Simulation Model created for Advanced simulation course in ARENA.
Phase 1: Concept Development
Identify Customer Needs - Interpret
Needs Statements:
 The customer would like to Invest time and money in the MSD project to
get a quality tools and tangible process improvement ideas.
 The results of this project should generate computer tool which would be.
•
•
•
•

accurately represent the real needs of the distribution center.
require minimum training and is user friendly.
alert the user when a given demand input is not realizable given actual capacity of
facility.
visualize all the information on a single screen.
The customer would also like the team to suggest validated process
improvement ideas to improve order picking and workforce utilization.
 The facility at Henrietta , is going through process improvement changes
to better order fulfillment time , customer satisfaction and streamline
their distribution.
 List of suggested 30 to 50 different improvement tasks.
 Some primary needs are worked on by current MSD team and next few
tasks need to be completed by future teams.
Affinity Diagram.
Order picking and
shipping
Demand
forecasting
Workforce
Utilization
• Decrease order
picking time.
• Decrease order
shipping time
• Increase order
picking accuracy.
• Ship orders
within target
times.
• Indicate any
trend in weekly,
monthly , yearly
demand.
• Indications of
seasonal
demands of
specific products.
• Determine daily
requirement
• Indicate if
enough
workforce is
available to fulfill
requirement.
• Have work force
utilization close
to 100%
Objective Tree
We need
this product
because …
Orders need to
be shipped
earlier.
No Mistakes in
picking
No reworking
We need better
level of customer
satisfaction.
Faster picking
required.
Labor needs to
be utilized
efficiently
Maximum
workforce
utilization.
High worker job
satisfaction.
Low variable
costs.
Orders shipped
earlier than
expected.
High quality of
products
shipped.
Correct
packaging and
labeling.
Function Tree
This project
Needs to …
Forecast trends in
the weekly, monthly
& yearly demand.
Indicate Daily labor
requirements.
Be easy and quick
Show detailed
requirements
Alert if under
staffed.
Improve Picking
system
Decrease picking
time.
Ergonomic
consideration.
Eliminate mistakes
and rework
Allow enough time
to hire more
workers.
Indicate changes to
the manufacturing
facility
Help in making key
decisions.
HOQ Main Body
VOC to VOE
Orders need
to be shipped
earlier
We need
better level of
customer
satisfaction
Labor needs
to be utilized
efficiently
Forecast trends in
Indicate Daily labor
the weekly,
requirements.
monthly & yearly
demand.
Improve Picking
system
5
1
9
3
7
7
9
7
5
Future Plan
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Discuss and finalize Staffing requirements
Discuss and finalize Resource requirements.
Schedule Meetings and Interview key stakeholders.
Attend Final design review and poster presentation of the
current MSD 2 team.
Document Team Values and Norms.
Determine preliminary Work Breakdown Structure.
Make and present Final Presentation too include.
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Planning:- Mission Statement ,Project Relevance, Staffing ,
Requirements, Intellectual Property Considerations.
Final Customer Needs :-Final Affinity Diagram, Objective tree,
Function tree and HOQ.
Issues & Risks mitigation plan
Make Marketing Video for future MSD I, MSD II students.
Preliminary Schedule
Wk 6
Wk 7
Wk 8
Wk 9
Wk 10
Staffing
requirement
Create work
breakdown
structure.
Start
working on
Marketing
video.
Start
working on
final
presentation.
Present all
Deliverables.
 Attending Mid-quarter Design review.
 Planning to attend
 Future customer feedback meetings.
 Final design review
 Poster presentation
Thank you