Abstract
This paper describes a case study for improving the productivity of distributive processing in a distribution center. The improvement of productivity was required to respond to the growth of the mail-order business. Distributive processing consists of picking, sorting, checking and packing. First, a work analysis was implemented and it was shown that the detailed work of checking had been preventing the distributive processing from boosting output. In this process, items were all checked by hand using bar-code scanners. Two systems, an automatic checking system using RFID and an assortment system, were considered for introduction in order to improve the flow of work at the bottleneck. Field tests were conducted using these two systems. The result of the field tests showed that both systems were able to resolve the bottleneck. However, the assortment system was eventually chosen because it does not overlook items and allows 100% accuracy of assortment. Additionally, reassignment of workers was carried out in order to balance out work load and to resolve the new bottlenecks. In the end, the productivity of the distributive processing was improved 42% three month later.
