Title Page

  • Document No.

  • Audit Title

  • Client / Site

  • Conducted on

  • Prepared by

  • Location
  • Personnel


Best Practices

  • 1. Place a stack of sleeves onto pallet while the clamp truck is dumping a container

  • 2. Only cover bar codes on sleeves, do not “over label”

  • 3. Have extra rolls of labels stored close at inspection station prior to start of shift

  • 4. Ensure travelers are restocked at the inspection station prior to start of shift

  • 5. Toss sleeves into stacker bin rather than walking them over and then placing them into bin. This saves time and allows inspector to stay in place and continue inspecting

  • 6. Move labeling machine closest to where the most amount of sleeves are within the inspection station to reduce inspector movement

  • 7. Ensure empty pallets are replenished in designated shadow boxes to reduce travel time

  • 8. Place temporary vertical guard at edge of inspection station to eliminate sleeves from falling out of the inspection station during clamp truck dumping

  • 9. Store traveler in standard location to reduce time needed to locate them

  • 10. The most efficient inspectors sort sleeves that do not need a label within inspection house. They do not gather piles and then sort them outside of the house

Additional Improvement Opportunities

  • A. Convert traveler to barcode with adhesive backing to eliminate writing and reduce application time outside of the house

  • B. Install signaling Andon system to indicate when an inspection station needs material replenishment

  • C. Leave partial pallets at end of shift to reduce double handling


Best Practices

  • 1. Ensure travelers are restocked prior to start of shift

  • 2. Keep traveler and adhesive in standard location and/or convert to bar coded traveler (i.e., at columns in PHL)

  • 3. Operators should keep scale jacks up once they are lifted off of the floor for the first time. This save the operators from having to pump it up to weigh it again

  • 4. Empty pallets should be close to inspection stations to minimize the travel time required to retrieve an empty pallet

  • 5. Stack directly on pallet vs floor or table to reduce double handling, transfer time and compression frequency

  • 6. Place a stack of bags on working pallet while waiting for clamp truck to dump

  • 7. Best inspectors do not look at current bag in process of being stacked after they snap it. They are looking at the next bag they are planning to inspect as they simultaneously place the current bag onto the stack.

Additional Improvement Opportunities

  • A. Add scale jacks between every station

  • B. Place a pallet on top of the bag stack when it is completed to help weight it down to reduce manual compressions and help with stabilizing during transport to shrink

Tray Unloads

Best Practices

  • 1. Lift one flap up on the underside of the box to stand the box up on. Then go around to the remaining flaps and stand them up so that all contents can be emptied straight to the floor without having to tip the box or remove trays stack by stack

  • 2. Always unload and stack on the inspector side rather than on back side of containers”

  • 3. Unloaders should push up four (4) stacks (2x2) at a time into inspection area rather than just one or two stacks at a time

  • 4. Toss condemned trays toward the condemned area rather than walking it back to reduce travel time. Clean the area up during slack time or at the end of the shift

  • 5. Leave 3 foot gap between rows of containers to provide a walking path to cardboard/mixed MTE area to prevent walking around the entire row

Additional Improvement Opportunities

  • A. Andon Signal to notify dock unloaders to push material into processing area

  • B. Place mixed MTE and trash receptacles at borders of processing area to minimize unloaders travel time

Tray Inspectors

Best Practices

  • 1. Ensure travelers are restocked at the inspection station prior to start of shift

  • 2. Ensure empty pallets are placed in shadow boxes and replenished periodically

  • 3. Push stacks to pallet area in close proximity to the pallet that is being worked on and start building pallets closest to largest stacks of common trays types

  • 4. Use the foot to lift stacks onto pallet

  • 5. Separate trays in the unload area and only push up finished stacks of EIRs to pallet area

  • 6. Count only one stack then even off other stacks with counted stack (exceptions are large plastic and cardboard trays)

Trailer Unload

Best Practices

  • 1. Always fully open door before engaging dock ramp to assure ramp will clear threshold into trailer

  • 2. Use shoring straps to temporarily hold a damaged container together while it is removed to reduce the probability of MTE falling on the floor while transporting

  • 3. Temporarily stage containers close to the door of the truck then move several boxes at one time to the main staging area

  • 4. While in the trailer, periodically step off the lift to see what the next few visible boxes contain in order to anticipate when to temporarily stage similar product close to the trailer door or go ahead and take the load to processing area

  • 5. While in the trailer and off of the lift, manually move small quantities of mixed MTE into boxes of well sorted MTE

  • 6. As last load is removed, stop just outside of the door and close truck out so that it can immediately be taken away from the dock. Do this before taking the last load of material back to staging area

Additional Improvement Opportunities

  • A. Drivers spend time in the temporary area rotating pallets to ensure correct alignment

  • B. Each driver fills out the dock sheets on second shift vs one lead performing this task on first shift. Which is best?

Clamp Driver

Best Practices

  • 1. Lift pallet off of the floor before closing clamps around box

  • 2. Angle clamp truck while dumping sleeves such that the momentum of the sleeves is directed toward the front left or right corner of the inspection stations to reduce the probability of sleeves spilling out the front of the inspection stations (start at 10-15 degrees and increase angle to about 45 degrees as sleeves start falling out of box)

  • 3. Simultaneously lift clamp while moving toward house, do not wait to get to the house and then lift.

  • 4. Temporarily stage empty containers and then push them back in a longer row to cardboard processing

  • 5. Define designated locations for mixed MTE bins in staging area

  • 6. Define and set boundaries in cardboard area to eliminate it from encroaching into staging area


Best Practices

  • 1..Band each pallet one at a time instead unwinding a long strand of material and working through a row of pallets. The long strands also create a tripping hazard.

Stretch Wrapper

Best Practices

  • 1. Lift pallet jack high enough so that you can see wheel alignment and not get caught on the conveyor entry ramp

  • 2. Assure parallel processing is taking place and that no machine is sitting idle

Additional Improvement Opportunities

  • A. Place a fixed, continuous scanner over placard printer to instantly scan placard into inventory once the label prints off.

  • B. Develop and deploy conveyor preventative maintenance program

Container Repair

Best Practices

  • 1. Always scan container before making repairs to assure that it is in inventory. If it is not then credit for the repair will be delayed until USPS puts it into the system

  • 2. Pull multiple containers together (in a train when possible) when moving to and from staging area to minimize walking

  • 3. During first shift, the Transporter removes the repaired containers from the staging area. During second shift, the Transporter pushes containers close to repair bays to start work the next morning

  • 4. One experienced repairman states that the optimal number of containers to “train” is 10 ER/GP (with power equipment)

Additional Improvement Opportunities

  • A. Have separate airlines for each pneumatic tool rather than having to switch lines between tools

  • B. Organize repair parts small bins at each workstation

  • C. Develop and deploy repair tool preventative maintenance program (especially for riveters)

Trailer Loader

Best Practices

  • 1. Stack up pallets to 45 high on side by side stacks and then move a stack of pallets on each fork (transporting two stacks at a time) to the staging area

  • 2. Temporarily stage two pallets toward the entrance of the trailer and then push that stack back with the next stack. This way the driver only has to make one long trip to the front of the trailer and back instead of two.

Additional Improvement Opportunities

  • A. Placard process needs to be streamlined and standardized: •On nights drivers go to the logistics office to retrieve them. –Is there a way to batch placards by trailer rather than printing 30-40 at a time? •On days drivers go to the dock terminal and print their own. –For printing at the dock terminal assess a way to speed up the entry in the screens rather than having to manually type in repetitive fields for individual placards.

  • B. Improve shoring strap management system. •Bad straps should have their own container and designated location to eliminate mixing them with good straps and then attempting to reuse them and wasting time. •Straps that come on trailers could be considered MTE that needs to be inspected and processed. They could automatically go into the ‘bad strap’ container to be sent to processing like all other MTE •Only inspected/rubber banded straps should be used to secure loads on trailers

Cardboard Processing

Best Practices

  • 1. Set up pallets close to the entrance of the bay so that as things come in they can be immediately broken down and palletized.

  • 2. Develop a standard layout: •Place pallets and boxes on both sides of each bay so that stacking is close no matter which side the material comes in. •Have a box or pallet in each hand when moving toward the stacks in order to minimize trips to retrieve material •Prevent daily reshuffling of area layout from shift to shift

  • 3. Break down smaller boxes en route to stack.

  • 4. Take larger boxes to the stack and break them down on top of the stack.

  • 5. Alternate the side of the stack that the ridged part of the large boxes is on so that the stack remains level and stable on the pallet

Additional Improvement Opportunities

  • A. One operator suggested placing a pallet between the backs of houses to stack the loose cardboard on rather than just dropping loose boxes onto the floor •Each clamp driver can push as many as 7 pallet/box combinations back at one time •This creates opportunity to damage the boxes when the clamp drivers have boxes on the floor rather than the pallet •One person estimates they have 1000 condemned boxes each week on their shift alone •However, there is no difference in payments between serviceable and condemned

  • B. Assure everyone is clear and consistent on standards for classifying serviceable vs condemned cardboard

  • C. Other layout ideas: •Have a designated place for a small box to place shoring straps in •Have a designated safety zone defined and marked just like in inspection houses. This would let the clamp drivers know when it is safe to push more material in

Yard Truck Drivers

Additional Improvement Opportunities

  • A. Know the content of trailers •Have Logistics Clerk speak with Transport Drivers about content of trailers as they are dropped off – make this an expectation for fleet drivers to know •If fleet driver does not know contents then determine secondary method to gather the information via yard drivers, logistics clerk, supervisors, leads, etc. •Each shift, have a requirement to have logged the oldest arrival time first and then to have at least the next shifts worth of trailers that need to be unloaded •Enter trailer content into MTES notes •As yard driver calls in for next move then call out trailer that satisfies the mix needed to keep production steady on the processing floor

  • B. Have assigned docks for trailer mix •Assign designated docks for trailers by content type •Assure dock assignments correspond to the shortest distance to the processing area that the material needs to go to •Once yard drivers are aware of trailer content, they should dock the trailer at the correct door for the MTE that they have


  • 1. Combine Logistics Clerk function with the warehouse Supervisor function to reduce headcount by one and improve denominator of LOE •Assure dock assignments correspond to the shortest distance to the processing area that the material needs to go to •Once yard drivers are aware of trailer content, they should dock the trailer at the correct door for the MTE that they have

  • 1. Combine Logistics Clerk function with the warehouse Supervisor function to reduce headcount by one and improve denominator of LOE •Assure dock assignments correspond to the shortest distance to the processing area that the material needs to go to •Once yard drivers are aware of trailer content, they should dock the trailer at the correct door for the MTE that they have

Management Control and Reporting

  • 1.  Site conducts Shift Handoff/Daily Production Meeting

  • 2.  Site follows prescribed agenda for Shift Handoff/Daily Production Meeting

  • 7.  Site follows Gemba Walk Topic Rotation Schedule from Playbook

  • 3.  Site completes Shift Turnover Sheets Daily (or on both shifts if applicable)

  • 4.  Site conducts Shift Start Up Meeting

  • 5.  Shift follows agenda for Shift Start Up Meeting

  • 6.  Site conducts Gemba Walks at least once per shift

  • 8.  Site participates in Program Weekly Review Meeting

  • 9.  Site actively manages action items from all MCR meetings within the site RAIL

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