ST-04 · Project dossier
Dachser · Mohammedia · final-year internship (bachelor’s degree)February – May 2022
Non-conformities were handled on paper forms, and the follow-up of the activity lacked a dashboard.
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PDCA
Plan
Scroll: the platform changes action by action
No.
01
Phase
Plan
Area
Platform
On Dachser’s platform in Mohammedia, the activity is growing and the administrative staff spend a lot of time writing. Goal: gain productivity and give the logistics manager a tool to manage performance.
No.
02
Phase
Plan
Area
Logistics office
When an anomaly is found, its photo and its reason go to the customer by e-mail. After that, nothing: no follow-up, no indicator to decide.
Finding
The follow-up of non-conformities is poorly managed.
Why?
There is no traceability.
Why?
Non-conformities are sent by e-mail, and e-mails get forgotten or deleted.
Why?
Root causeNo file gathers all the non-conformities.
No.
03
Phase
Do
Area
Receiving
Brainstorming with the logistics manager and two administrative staff, then data collection: the types of anomalies (Ishikawa, Pareto) and the step of the flow where they appear.
Anomalys
Steps
No.
04
Phase
Do
Area
Non-conformity form
A new Excel form with drop-down lists and a date picker, and three VBA macros: the form goes to the customer as a PDF, its data join the traceability file, then it clears itself for the next one.
Non-conformity form
drop-down lists, date picker
Macro 1PDF and e-mail
the form is converted to PDF and sent
Macro 2Traceability
the data are added without overwriting what is there
Macro 3Reset
the form is cleared and saved for the next entry
No.
05
Phase
Do
Area
Traceability file
All non-conformities arrive in a single file, with their indicators: at last there is an overall view.
No.
06
Phase
Check
Area
Logistics office
Handling a non-conformity, converting it to PDF and sending it to the customer took 12 minutes with the old form. With the new one, 5 minutes.
No.
07
Phase
Act
Area
Non-conformity form
The form is put in place across the whole logistics department. To overcome the difficulties of getting started, a procedure sheet supports the training of the administrative staff.
No.
08
Phase
Plan
Area
Platform
Second workstream: the utilisation rate. Each step, from pre-receiving to shipping, is timed. Everywhere, the administrative tasks or those given to a single operator weigh the most.
Pre-receiving
inspection and opening of the truck
Receiving
sending the report and updating the tracking table
Put-away
storage
Picking
creating the order in the system
Shipping
loading validation and follow-up
Detailed times not published
No.
09
Phase
Do
Area
Dashboard
An automatic Excel dashboard, fed by the time studies and by the inbound and outbound pallet flows of each unit.
Utilisation rate
Planned hours / assigned hours
Handling unit flows
Full-time operators needed per unit and per month
Activity trend of each customer
Real indicators · values not published
No.
10
Phase
Act
Area
Dashboard
With the logistics manager, clear rules based on the gap between hours worked and hours assigned, to justify reinforcement, recruitment or training.
Hours worked > hours assigned · a few days
→ reinforcement from a less busy unit
Hours worked > hours assigned · 1 to 3 months
→ fixed-term hire for the time needed
Hours worked > hours assigned · 6 months or more
→ renewable one-year fixed-term contract or permanent contract
Hours worked < hours assigned
→ training, order picking during quiet times