Nabisco: productivity at the speed of sound

摘要

Several years ago when the logistics professionals at Nabisco did a cost study of warehouse operations, it learned that for all the various tasks performed, orderpicking represented the highest cost per unit. So orderpicking became the area it targeted for its technology-saving initiatives. Karen Mattke, manager of logistics productivity, says Nabisco narrowed the search to two possible solutions: pick-to-light and voice-directed order selection systems. "We didn't do any actual pilot studies with pick-to-light, but we looked at a lot of companies and the numbers they achieved," says Mattke. "It [pick-to-light] offered the kinds of productivity we were looking for, but was cost-prohibitive." Further study indicated voice-directed systems could offer the same kind of productivity benefits, and at a reduced cost. However, there were some glitches in the available voice-directed programs. Those original studies were completed a few years ago, just as voice-directed systems were becoming available. Then, hardware was a major problem. "The equipment was ergonomically not right," says Mattke. "Headsets were too heavy and cumbersome. And they were not rugged enough for distribution center conditions." So Nabisco stuck with its paper-based system and did more studies. About a year ago it undertook a major comparison study at one of its Boston-area branch warehouses, using a paper-based picking line in direct competition with a voice-directed line. Its paper-based system was already relatively fast, so the potential productivity benefits were in order accuracy. "The end result of that study proved to us that we could get the productivity gains we were seeking," explains Mattke, "at a fraction of the cost of other systems." In addition, Mattke says, "We liked the flexibility of voice. Pick-to-light was hard-wired in along the conveyor, and that is all it did.