Observation Session: Warehouse Operations

Date: [Insert Date]
Duration: 4 hours (9:00 AM to 1:00 PM)
Observer: [Your Name]
Employee Being Observed: [Employee Name], Warehouse Operator
Location: [Warehouse Name/Address]

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Objectives

1. Understand the daily workflow of warehouse operators.
2. Identify inefficiencies and pain points in the current processes.
3. Gather insights on how technology could streamline operations.

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Preparation

1. Obtain permission from warehouse management and the employee being observed.
2. Review basic information about warehouse operations to understand terminology and processes.
3. Prepare a list of tasks or activities to observe, such as receiving inventory, picking items, and packing orders.

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Observation Plan

1. Arrival and Introduction (9:00 AM – 9:15 AM)
   • Meet with the warehouse operator and introduce yourself.
   • Explain the purpose of the observation and ensure the employee is comfortable.
   • Emphasize that the observation is not an evaluation of their performance but a way to understand processes.
2. Observation of Tasks (9:15 AM – 12:45 PM)
   • Follow the warehouse operator as they perform their tasks.
   • Take detailed notes on the steps involved, tools used, and any delays or issues encountered.
   • Observe the following activities:
     1. Receiving Inventory: How items are checked, logged, and stored.
     2. Order Picking: The process of retrieving items from the shelves to fulfill an order.
     3. Packing and Shipping: How items are packed, labeled, and prepared for shipment.
   • Note the use of any software, hardware, or manual processes involved in each task.
3. Informal Questions and Clarifications (During Observation)
   • Ask clarifying questions when appropriate, such as:
     • “What do you do if an item is damaged or missing from inventory?”
     • “How do you decide where to store new inventory items?”
     • “What are the most time-consuming or frustrating parts of this process?”
4. Wrap-Up and Debrief (12:45 PM – 1:00 PM)
   • Thank the employee for their time and insights.
   • Ask if they have any suggestions for improving the current processes.
   • Explain the next steps, such as documenting findings and presenting recommendations.

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Notes and Observations

1. Receiving Inventory:
   • The operator uses a handheld scanner to check items against a printed inventory list.
   • Issues observed: The scanner frequently loses connectivity with the warehouse management system, causing delays.
   • Items are manually logged into the system, which can be time-consuming.
2. Order Picking:
   • The operator uses a paper-based picking list to locate items in the warehouse.
   • Inefficiencies: The operator spends a lot of time walking back and forth between aisles due to a lack of route optimization.
   • Items are sometimes difficult to find due to inconsistent labeling.
3. Packing and Shipping:
   • The operator manually packs items and labels packages using a desktop computer and label printer.
   • Pain point: The operator mentioned that the label printer often jams, slowing down the process.

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Key Pain Points Identified

1. Connectivity issues with the handheld scanners cause frequent delays.
2. The paper-based order picking system results in inefficiencies and extra walking.
3. Inconsistent labeling makes it difficult to find items quickly.
4. The label printer is unreliable and slows down the packing process.

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Initial Recommendations

1. Consider upgrading to more reliable handheld scanners with better connectivity.
2. Implement a digital order picking system with route optimization to minimize walking time.
3. Standardize labeling across the warehouse to make items easier to find.
4. Invest in a more reliable label printing system or schedule regular maintenance.

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Follow-Up

1. Schedule a meeting with the warehouse manager to discuss findings and potential solutions.
2. Explore software options that could streamline order picking and inventory management.
3. Plan additional observation sessions with other employees for a more comprehensive view of warehouse operations.