I figured a couple of pictures is worth 1000 words. This is not the only time we one a contest put on by the Pacific Region. Every hub sort participated.
Picture 1 - Entire supervisor crew - I am the one kneeling - Jackets picked by supervisors and the Pacific Region paid for them
Picture 2 - Supervisor of the Year - Every month and every year I ranked the supervisors and picked Inbound and Outbound supervisors of the month. At one point I had 35 supervisors.
In December of 2002, the mistoggle frequency was 4620 and the missort frequency was 4592. When I started the frequencies were under 400. Loaders were averaging 350 plus an hour.
This can be done and it is not hard. You don't have to sacrifice performance for it. Remember - my operation hit these frequencies in DECEMBER. During peak week, volumes averaged 120,000 a day with process rates of 20K an hour.
KEY POINT - If you do things right - you get better with more volume not worse.
If you use the 21 point checklist and follow it - you can achieve remarkable results. You can get results within days of starting this process.
Key Elements -
Awareness - hold meetings with loaders -let them know the goals and how to achieve results
Methods - scan every package - don't jam packages down the loaders throats. Know their PPH and let them know what you expect them to increase to.
Sups needs to do 3 min drill every hour with each loader
Key in on the (80/20 concept) 20% destinations which are causing 80% of the problem.
Lock your loaders into the same load - test them on knowledege
Salt them randomly and daily
Make sure every loader knows what the targeted loads are for the week. You need buy in and loaders and pickoff working together to achieve the results. They are each responsible.
RECOGNIZE RESULTS - even in this economy you can do things to recognize your employees' efforts that don't cost you and arm and a leg. A simple and sincere "Thank You" goes a long long way. Create a missort club. Serve food once in awhile - let everyone see who is being recognized and why.
This stuff works - Here are a couple of pics that prove it. A good supervisor is the same as a good coach. All the same kind of processes are in play. You prepare - you drill - you get to know and RESPECT your people - and you celebrate success.