Shipping error reduction from 4.2% to 0.6% in 5 months
Implementation of a visual control system and reorganization of packing stations at a production plant near Tczew.
Tczew-Tech Components was losing money on free shipments of missing parts. In five months, we fixed the packing process by introducing simple pictorial instructions and a new table layout. We went from an error level of 4.2% to just 0.6%.
The challenge
The plant shipped an average of 3,240 packages monthly. Statistics from December 2023 showed that 136 shipments contained errors – either a screw was missing or the gasket model was wrong. The cost of claims, return courier fees, and wasted employee time was nearly 18,360 PLN monthly. Chaos reigned because every packer had their own way of arranging goods on the counter, which led to distraction.
Our approach
In February 2024, we spent four days on the floor measuring the time of every movement of 14 employees. A team led by Marek Wiśniewski identified 4 main points where employees lost focus. Instead of buying expensive scanning systems, we focused on visual control. We introduced a rule that every package must look identical before closing the carton.
The solution
We rebuilt 7 packing stations. Boards with large photos of a correctly packed set were hung above every counter, eliminating guesswork. We introduced a shadow system on the worktops – every element of the set has its own drawn place. We also changed the document flow system; now the checklist is taped to the side of the box only after a physical content check by the shift leader for orders above 4,750 PLN.
Results
The effect came faster than we assumed in the original plan. By June 2024, the number of mistakes dropped to 19 for the entire month, which drastically lowered reverse logistics costs.
Timeline
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February 2024Audit of 124 processes on the floor and work time measurements.
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March 2024Construction of a station prototype with a shadow system.
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April 2024Training for 14 day-shift employees on the new rules.
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June 2024Results summary and implementation on all shifts.
"Previously, we argued with customers about missing items every two days. Now the phone is silent, and we ship goods faster by nearly fifteen minutes per package. Numbers don't lie, it was a good decision."