For those of you who are currently tasked with making operational and/or systematic changes, you may now be facing your greatest challenge – sorting out assumptions/presumptions and getting down to the facts. The following includes two of what I believe to be the most common examples to beware of:
1. The first example is a type of assumption that says the “Suggested Problem” (such as inventory costs or customer order response times) is technologically fixable.
Inventory costs, for example, might be caused by inflated (or inaccurate) sales projections. Or it could be there’s an unusually high rate of returns for certain items, and those returns aren’t calculated against projected inventory levels.
In the case of response times, if the company wants 90 percent of orders filled and shipped within 24 hours and it typically takes 18 to 20 hours just to get the order approved and downloaded to the DC, there’s not much you can do even with the most efficient physical processing system.
In these situations, all you can do is try to calmly point out opportunities for improvements in other areas to make your area more efficient. And, in fact, better communications between departments can lead to great improvements in efficiencies such as faster response times and more accurate sales forecasting.
2. The second example is a type of presumption where the “Suggested Problem” is the real problem. It’s this type of presumption that is most dangerous. It’s where presumptions are mistaken for facts.
Let’s say the presumption is that order fulfillment takes too long because the packing area is inefficient. Is this really the problem? If, say, you have six packing stations, each equipped with a hand-held scanner to verify the shipment, perhaps fixed-location or wearable scanners might improve operations by as much as 10 percent (depending on the number and type of items being packed).
But, could the process be improved more dramatically by scanning and verifying the shipment as it’s picked directly into the shipping container? In some applications, this could eliminate as much as 50 percent of the activity in packing and could significantly streamline order fulfillment. It might even allow you to assign some of your packers to picking.
If you accept the presumption that the problem is in the packing operation as if it’s a fact, you miss the opportunity for making broader improvements.
Take another example - returns, which in many companies is a significant factor. Here the assumption/presumption might be that you need to streamline returns by allowing customers to use the Internet to generate returns labels complete with bar codes. It’s true that scanning these bar codes can facilitate returning material to stock and adjusting inventory or directing returns to an appropriate processing area in the case of defects or damage.
But, if those data aren’t (or can’t be) shared with Accounting, Sales and Marketing, they’re not being used properly (or completely). Whether the data are shared upon receipt of the returned item or taken directly from the Internet depends on how the company operates. Here again, if you presume that the returns processing area is the only place you need to make improvements, you may be missing an opportunity - and possibly overlooking the root cause of the problem.
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