We experimented with different distinguishing features, when it comes to the car designation. 1 & 4, 5 & 6, 8 & 9 are very similar in appearance as we use a font, which makes these numbers so close. We looked into methods and procedures, and even good loaders, following the methods and acknowlwdging the PALs inside the cars signed of the package in the wrong car.
Distinguishing colors would definitly help, as it all comes down to the the following course of action:
Ideal: a robot-like vision recognition of package caracteristics (PAL number) and conversion into motion (right car/right/shelf/right placement in sequence) based on a hard-wire device (computer) and software system, providing the correct instructions
Current: The human brain is the center and drive for visual recognition of package characteristics as well as giving the proper instructions for motion, all driven by the flow and workings of neurons and synapses (similar to a circuit board and wiring diagram). However there are gaps in this wiring diagrams, and that is where the synapses and neurons come into play. The neurons have to hit the right synapsis, resulting in the transfer of proper instruction for conversion into motion. Counterchecking the PAL inside the car is the last transaction in this chain of events. If everything works out fine (everything is in the proper place), then it has worked. But I have also seen good loaders, following the methods, who sign off the PAL inside the car, and it is still in the wrong car.
And when it comes to the end of the sort (with the intense pressure to wrap), then the mistakes happen, especially when other loaders are assigned to cars, and the accountability cannot be maintained (but we may have wrapped in time, hurray).
What is the solution? As I have written in the beginning (and this might appear as harsh), remove the human element at least from sorting on the slide, so that all boxes and envelopes are placed in front of the right car. Is it feasible? Possible. Is it feasible in view of the current layout from the pick station to the individual slides and flowrates? Would it have a positive financial effect to adjust
- flow rates
- layout of belts/slides?
Would it have a positive financial impact to have more suitable and capable personnel, beginning with the selection process?
I am with this company for a few years, and regrettably I have seen only a more intensive banging of our heads into a concrete wall when it comes to the entire unloading and loading process with more damages and misloads.
Trying to conduct misload audits at the end of the sort is possible only in extremely rare cases, and this is the time when it happens, especially when additional loaders are trying to wrap the cars. Trying to conduct MORE misloads audits does not correct systemic deficiencies, we only try to stops the leaks.
To me it appears as if the current system is in exact opposition to perform a quality operation, but maybe this has been calculated by controllers as being the cost of business. Who knows? We will know when the customer tells UPS in an unmistakably manner what they would like to do, but currently what kind of an option do they have? Do you think the others are better? And I am a customer too.
The overall "envelope" of this operation has not changed, but the company tries to push more into this envelope, and it looks as if it expects a simple linear increase/improvement in flow rates would have a beneficial financial effect. The "envelope" might still offer a few more nooks and crannies to fill, but it als very close to bursting apart, as we do not change the size of the "envelope".
