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Merchandise Unlimited
  UPS Truck Crew Process Evaluation
                      Final Report

Evaluation Team: Eboni DuBose, Perri Kennedy, and Chester Stevenson
                  IPT 530 Evaluation Methodology
                       Boise State University
                            Spring 2011
Table of Contents


Preliminaries ................................................................................................................................... 2
   I. Executive Summary .................................................................................................................. 2
   II. Preface ..................................................................................................................................... 4
   III. Methodology .......................................................................................................................... 5
Foundations .................................................................................................................................... 6
   1. Background and Context ......................................................................................................... 6
   2. Descriptions and Definitions ................................................................................................... 7
   3. Stakeholders .......................................................................................................................... 12
   4. Resources .............................................................................................................................. 12
   5. Dimensions of Merit and Importance Weighting ................................................................. 14
Sub-Evaluations............................................................................................................................. 15
   6. Process Evaluations ............................................................................................................... 15
   7. Exportability .......................................................................................................................... 17
Conclusions ................................................................................................................................... 18
   8. Overall Significance ............................................................................................................... 18
   9. Recommendations ................................................................................................................ 21
   Reporting ................................................................................................................................... 23
References .................................................................................................................................... 24
Appendix A: MU UPS Receiving Process Assessment Rubrics with Criteria Highlighting ............. 25
Appendix B: Summary of Ratings with Rationale ......................................................................... 28
Appendix C: Data Sources for Instrument Dimension .................................................................. 29
Appendix D: Data Sources for Workspace Dimension .................................................................. 31
Appendix E: Data Sources for Process Management Dimension ................................................. 34
Appendix F: Sub-dimension Weighting of Importance by Stakeholders ...................................... 38
Appendix G: Scoring Rubrics for MU UPS Receiving Process Evaluation ..................................... 39




                                                                         1
Preliminaries
I. Executive Summary
Introduction
Merchandise Unlimited (MU, pseudonym), a merchandise distribution company based in the
Midwestern region of the United States, had not examined the processes and resources in
place to receive inbound shipments for at least a decade. The Director of Operations and the
Operations Manager requested a formative evaluation to both establish how well the inbound
receiving process (hereinafter referred to as “evaluand.”)should function and discover how well
it actually does function.

In the spring of 2011, three graduate students (hereinafter referred to as “evaluation team”)
from Boise State University’s Instructional & Performance Technology program were asked to
conduct an evaluation of the inbound receiving process. The stakeholders asked for the
evaluation team to look specifically at the 10-person truck crew (hereinafter referred to as “UPS
Truck Crew”) which offloads and sorts inbound shipments of used and returned merchandise
which were delivered via the United Parcel Service (UPS). The evaluation team created
assessment rubrics based on industry best practices and the needs of MU, and then examined
the practices and resources in place.
Methodology
The evaluation team conducted a formative goal-based evaluation structured on Scriven’s
(2007) Key Evaluation Checklist. It was designed to examine the current state of the UPS
receiving process and how it could be improved. After discussions with the stakeholders, the
evaluation team focused on three dimensions:
        Instruments
        Workspace
        Process Management

Each dimension was weighted based on the stakeholders’ consensus determination of its
importance (Important, Very Important, or Extremely Important). The evaluation team created
an assessment rubric based on warehousing best practices, and then compared the current
processes and resources in use by the UPS Truck Crew to the assessment rubric.

Conclusions
Using a 5-point scale (Poor, Mediocre, Acceptable, Very Good, and Excellent), the overall
quality of the UPS receiving process is rated “Acceptable” for current organizational needs.
However, the evaluation team concluded that the current set of processes and resources may
not be sufficient to handle future needs. A major concern is that Process Management,
weighted as Extremely Important by the stakeholders, was rated as “Mediocre” when




                                               2
compared to industry best practices. The overall evaluand rating and dimensions with ratings
and weighting are shown in Table 1.

                                                  Rating
   Overall
                                                      
  Evaluand


 Dimension                                                                                Weighting

 Instruments                                                                             Important
                                                                                             Very
 Workspace                                            
                                                                                          Important
  Process                                                                                 Extremely
                                       
Management                                                                                Important
                      Poor        Mediocre       Acceptable       Very Good   Excellent



Table 1. MU UPS Truck Crew Receiving Process Evaluation Results

Strengths
Based on the evidence gathered, the evaluation team noted the following strengths of the UPS
receiving process:
        Equipment in use is well maintained and sufficient to maintain current operation levels.
        Space is utilized as well as possible given its limitations.
        The supervisor and members of the UPS Truck Crew are capable, experienced, and work
        together as a cohesiveness unit.

Opportunities for Improvement
Based on the evidence gathered, the evaluation team made the following recommendations to
the stakeholders:

        Develop and document a standardized operating procedure to ensure that tacit
        knowledge is not lost and that new hires receive consistent on-the-job training.
        Develop performance metrics to drive continual process improvements.
        Develop a standardized package labeling system for use by retail and individual
        customers.
        Examine all options for increasing floor space.
        Evaluate existing hardware for possible replacement or upgrades to meet future needs.
        Look into a possible redundancy in the initiation process, and consider the options for
        having initiation performed at the next stage of the receiving process.


                                                      3
II. Preface

Background
Merchandise Unlimited, a merchandise distribution company based in the Midwestern region
of the United States, had substantially upgraded and modernized much of its warehouse
operations in recent years. However, the processes and resources in place to receive inbound
shipments had not been updated or even examined for at least a decade.

In January 2011, the Director of Operations and the Operations Manager of Merchandise
Unlimited requested an evaluation of the processes in use by the receiving department, which
handles all inbound shipments delivered to the company’s warehouse. Although other
warehouse processes had been assessed and improved, the receiving functions had not been
evaluated for many years.

The stakeholders asked for the evaluation to look specifically at the receiving process
conducted by the UPS Truck Crew, a 10-person workgroup which handles overstock and used
merchandise shipped back, via UPS, to MU in individual non-palletized packages. The volume of
shipments handled by this crew ranges from 1,500 to 3,500 packages each working day.

The Director of Operations and the Operations Manager stated that they planned to adopt any
recommendations which, in their judgment, will be both feasible and cost-effective to
implement within the next two years.


Evaluation Focus
This evaluation examined the merit of the UPS receiving process. The Director of Operations
and the Operations Manager wanted to assess the intrinsic quality of the UPS receiving process
and see how it compared to industry best practices. The purpose of the evaluation was to
develop the definition of merit for the receiving process, as the company had never established
any benchmarks or ideals of performance.


Evaluation Type
This project was developed as a formative evaluation, as the stakeholders wanted to
understand the current level of performance and what changes to the process or environment
could improve that performance. Formative evaluation is defined as one “typically conducted
during the development or improvement of a program… and it is conducted, often more than
once, for the in-house staff of the program with the intent to improve” (Scriven, 1991, pp. 168-
169).


Audience
This evaluation report was created for the Director of Operations, the Operations Manager, the
Inbound Manager, the UPS Truck Crew Supervisor, and the Vice President of Human Resources.


                                               4
III. Methodology

Evaluation Approach
When the evaluation project was proposed, the stakeholders had a general goal of improving
efficiency in the UPS receiving process; they defined efficiency as the speed, accuracy, and cost-
effectiveness of the overall process. However, no performance targets or ideals for the
receiving department had ever been defined nor was any system in place to measure speed,
accuracy or cost-effectiveness. Without any existing metrics against which to compare current
performance, it was impossible to determine efficiency based on the stakeholders’ definition.

After discussing this with the stakeholders, the evaluation team agreed to instead develop an
assessment rubric based on industry best practices and then evaluate how the UPS receiving
process compared to those best practices.

The evaluation framework was based on Scriven’s (2007) Key Evaluation Checklist (KEC), which
outlined a systemic examination of both processes and outcomes. Due to the lack of existing
metrics, this evaluation was conducted strictly as a process evaluation which would examine
the procedures and resources currently in use by the UPS Truck Crew. The methodology used
was a goal-based dimensional evaluation of the evaluand’s absolute merit, in that the
evaluation team identified dimensions of merit for the evaluand and then examined how the
procedures and resources utilized in each dimension compared to the best practices defined in
the assessment rubric.

To develop the assessment rubric, the evaluation team researched best practices for
warehouse receiving departments to determine ideal processes and identify key issues to
examine. The evaluation team also documented the current procedures and environment in
place to look for strengths and weaknesses in actual practice. The evaluation team developed
its assessment rubric based on industry best practices compiled by Supply Chain Visions and
sponsored by the Warehousing Education and Research Council (WERC). The evaluation team
then hosted a focus group with the Operations Manager, Inbound Manager, and the UPS Truck
Crew Supervisor to discuss the key elements of warehousing best practices. Some proposed
dimensions were eliminated as not relevant or not of sufficient importance. The remaining
dimensions were then shaped into a set of assessment rubrics which the evaluation team used
to identify the areas of greatest opportunity for improvement. The process assessment rubrics
are included as Appendix A.

Data Collection Methods
The evaluation team used a combination of data collection methods including interviews,
extant data, and observation. Specific methods used for each dimension of merit are identified
in Appendix C (Instruments), Appendix D (Workspace), and Appendix E (Process Management).




                                                5
Foundations
1. Background and Context
Merchandise Unlimited (MU) is a merchandise distribution company based in the Midwestern
region of the United States. MU has been in business in different incarnations for about a
century, and has existed in its current form for nearly four decades. Its primary objective is to
collect and distribute new and used products and ship them to its customers at the lowest cost
possible. MU’s single warehouse is in operation 24 hours a day, five days a week to receive,
sort, and distribute more than 20 million pieces of merchandise each year to both individual
consumers and the company’s 2,500+ retail clients. For many years, the primary concern of
warehouse management has been how fast products are shipped to the company’s customers,
so almost all efforts at efficiency and modernization have been focused on this area. The
current sorting and distribution areas of the warehouse make extensive use of modern
technology, including robotics and 3-D scanning, to ensure that products are shipped accurately
and rapidly.

Management has recently turned its focus on how fast products are brought into the building, a
process that has not been re-evaluated in over a decade. Out of all the products received in the
warehouse, approximately 75% are delivered by a single carrier, UPS. The operations
department would like to evaluate the existing UPS receiving process to improve inefficiencies
and reduce costs.

The stakeholders asked the evaluation team to conduct the first evaluation by focusing on the
10-person workgroup (the UPS Truck Crew) which handles offloading, sorting, and initiating
individual packages of overstock and used merchandise shipped to the warehouse via UPS; this
crew does not handle packages sent through other carriers, nor does it handle palletized loads.
This merchandise includes both retail store overstock and returns from individual customers.
The packages are classified by the UPS Truck Crew as large or small.

       Large packages: Shipments from retail customers
       Small packages: Shipments from individual customers, or internal mail

Constraints
Seasonal Fluctuations
Due to the nature of its business, MU experiences predictable and significant seasonal
fluctuations in both shipping and receiving merchandise through its warehouse. During normal


                                               6
times, the UPS Truck Crew may offload and sort 1,000-1,500 packages daily, most of which are
picked up by the receiving departments that same day. During seasonal peak times, the crew
may process as many as 3,500 packages daily; since the receiving departments cannot handle
this inbound volume immediately, the UPS Truck Crew must store the packages for later pickup.

Warehouse Space
The UPS Truck Crew’s assigned space was sufficient a decade ago, when the average daily
volume was approximately 800 packages. However, the average daily volume of packages has
nearly doubled since that time. No additional floor space is available for the crew’s use. The
storage area’s shelves are permanent fixtures which cannot be reconfigured or removed.



2. Descriptions and Definitions

Evaluand Description
The receiving department is broken into four sections:
       Truck crews, including the UPS Truck Crew, which unload the inbound shipments
       Receiving, which receives large packages from the truck crews
       Direct Receiving, which receives small packages from the truck crews
       Internal Mail, which receives small packages from the truck crews

The UPS receiving process begins when the UPS truck driver unloads packages from his or her
trailer onto a mechanical roller, which rolls the packages into the building. As each package
comes down the roller, a member of the UPS Truck Crew removes it from the roller and
examines its label. Large packages which are part of a shipment of three or more boxes are
sorted directly onto pallets and then initiated. One- or two-box shipments of large packages are
put on the express belts, initiated, and then sorted onto pallets. All small packages are put on
the express belts, initiated, and then sorted into bins. Large package pallets are picked up by
Receiving, and small package bins are picked up by Direct Receiving or Internal Mail.

During the initiation process, a crew member enters a package’s shipping information into the
warehouse inventory software using a laptop computer. Most package labels include UPS
barcodes, which are scanned using a USB device that feeds a limited amount of package
information into the warehouse inventory software; the crew member must initiate the rest of
the information into the system. During times of normal inbound volume, the pallets and bins
are picked up promptly by the destination department.




                                               7
When inbound volume is very high, the UPS Truck Crew moves the pallets into the storage area,
    where they may remain for up to two weeks awaiting pickup. A visual representation of this
    process is shown in Figure 1.



                   Packages unloaded by UPS employee from trailer onto mechanical roller




                        Packages removed from mechanical roller by UPS Truck Crew




                      Packages sorted by type and placed on wooden pallets (Receiving)
                          or onto express belts (Direct Receiving and Internal Mail)




            Packages initiated into inventory system using laptop computer and handheld scanner




       Normal receiving volume:                                               Peak receiving volume:
  Pallets (Receiving) and bins (Direct                                Pallets and bins stored on shelving for
Receiving and Internal Mail) prepared for                                          later pickup
           immediate pickup




            Pallets and bins picked up by Receiving, Direct Receiving, and Internal Mail employees




Figure 1. MU UPS Truck Crew Receiving Process.




                                                         8
Process Logic Model
The MU UPS Truck Crew Process Logic Model (see Figure 2) describes the factors and crew
activities involved in the UPS receiving process, what activities the evaluation team performed
in examining the process, and the intended results of the evaluation and subsequent changes
to the process.




Figure 2. MU UPS Truck Crew Receiving Process Logic Model




                                                     9
Definitions

Table 2 defines terminology used in this report, including evaluation concepts and terms used
by MU for elements involved in the receiving departments.

Absolute Merit                                The quality or value of something in absolute
                                              terms measured against a defined standard.
Assessment Rubric                             A tool which provides an evaluative
                                              description of what performance looks like
                                              at each of two or more defined levels.
Dimension of Merit                            Criteria of merit. These are aspects of an
                                              evaluand that define whether it is good or
                                              bad and whether it is valuable or not.
Dimensional Evaluation                        An analytical evaluation in which the quality
                                              of the evaluand is determined by looking at
                                              its performance on multiple dimensions
                                              (criteria) of merit.
Direct Receiving                              The division of the receiving department
                                              which opens small packages and sorts their
                                              contents for processing.
Downstream Impactees                          Impactees that are not directly affected by
                                              the evaluand.
Evaluand                                      That which is being evaluated (e.g., program,
                                              policy, project, product, service,
                                              organization).
Express Belt                                  A 10-ft long mechanical roller with a
                                              computer and scanner at the end, used to
                                              initiate individual packages.
Formative Evaluation                          An evaluation conducted for the purpose of
                                              improving a currently operational evaluand
                                              for the purpose of making improvements.
Goal-based Evaluation                         A type of evaluation based on the goals of
                                              the evaluand.
Inbound                                       Shipments coming into the warehouse from
                                              outside vendors or customers.
Initiating                                    MU terminology for the process of entering
                                              package data into the warehouse inventory
                                              software.
Internal Mail                                 Packages received which are not return
                                              merchandise. These packages are given to
                                              the company’s internal mail facility, which
                                              delivers them to the appropriate recipients.



                                             10
Mechanical Roller                                       A non-electrical device consisting of a series
                                                        of rollers which is used to transport boxes
                                                        from one area to another.
Merit                                                   Intrinsic value, quality or significance of the
                                                        evaluand.
Overstock                                               Excess merchandise in a store’s inventory,
                                                        which may be returned to the vendor.
Package                                                 Refers to a box, carton, or other shipping
                                                        container received. They are typically
                                                        referred to at MU as small or large
                                                        depending on their actual size.
Palletize                                               To load packages onto wooden pallets for
                                                        transportation or storage.
Primary Consumers                                       Actual or potential users of the evaluand.

Program Logic Model                                     A diagram that illustrates the cause-and-
                                                        effect relationships between resources and
                                                        activities, and the outcomes and impacts of
                                                        the program.
Truck Crew                                              A crew of MU employees which sorts
                                                        merchandise as it is unloaded from a truck
                                                        into the warehouse.
UPS Receiving Process                                   Refers to the operations involved in
                                                        unloading, sorting, and initiating inbound
                                                        packages.
UPS Truck Crew                                          The 10-person truck crew which processes
                                                        shipments of overstocks and used
                                                        merchandise delivered by UPS to the
                                                        warehouse. The UPS Truck Crew is the
                                                        primary consumer of this evaluand.
Upstream Stakeholders                                   Stakeholders who are involved in the
                                                        development, implementation, or
                                                        management of the evaluand.
Weight                                                  The determination of which evaluation
                                                        criteria are the most important.

Table 2. Definitions of Evaluation and MU Terminology




                                                        11
3. Stakeholders
This evaluation was concerned with three sets of stakeholders: upstream stakeholders, primary
consumers, and downstream impactees. The stakeholders are listed in Table 3.


 Upstream Stakeholders                    Primary Consumers         Downstream Impactees

 Director of Operations              UPS Truck Crew (n = 10)       Immediate Impact
                                                                   Direct Receiving staff
 Operations Manager                                                Receiving staff
                                                                   Internal Mail staff
 Inbound Manager
                                                                   Secondary Impact
 UPS Truck Crew Supervisor                                         Product stockers
                                                                   Product shippers

                                                                   Distant Impact
                                                                   External customers
                                                                   Clients of external customers


Table 3. MU Stakeholders for the UPS Truck Crew Evaluation.


4. Resources
Financial Resources
The UPS Truck Crew is funded by the organization as part of its Operations division. They
receive whatever funding necessary to perform their required tasks. The upstream stakeholders
stated that they are willing to spend money on changes which they deem likely to increase
efficiency and/or decrease operating costs. The stakeholders will not reduce costs through staff
reductions; if increased efficiency allows for a smaller UPS Truck Crew, extra crew members will
be moved to other parts of Operations rather than be dismissed.

Physical Resources
See Figure 3 for a simplified illustration of the physical layout. The storage area assigned to the
UPS Truck Crew is capable of holding between 65,000 and 75,000 packages on its shelving units.
The storage shelves are permanent fixtures which cannot be removed or reconfigured.




                                                      12
Figure 3. Layout of MU UPS Truck Crew Receiving Space

Knowledge Resources
The supervisor of the UPS Truck Crew has held this position for 15 years, and five of the ten
crew members have worked there for five or more years. Turnover is modest and not
considered by management to be an issue; morale within the crew appeared to be excellent.
New hires receive on-the-job training in sorting and initiating packages.

Technological Resources
The UPS Truck Crew inputs data from each package label into a laptop computer running
proprietary inventory management software. The software has a command-line interface. It
takes an experienced crew member approximately one minute to type in the data for each
individual package. The laptops in use are old and slow. The shipping labels on some packages
include barcodes, which are scanned using devices which connect to the laptops via a USB
cable. Data incorporated into the barcode is automatically entered into the inventory
management software, but additional data must still be entered manually.




                                                        13
5. Dimensions of Merit and Importance Weighting
The evaluation team met several times with the Operations Manager, Inbound Manager, and
UPS Truck Crew Supervisor to refine the focus of the evaluation. When the final dimensions of
merit were selected, the evaluation team conducted a group interview with these three
upstream stakeholders so they could weigh the importance of each dimension using a 3-level
scale (extremely important, very important and important).

The evaluation team then divided each dimension into sub-dimensions, around which it created
an assessment rubric. The dimensions, weighting, and sub-dimensions are shown in Table 4.

Dimension of Merit        Dimension Weighting                              Sub-dimension
                                                        Hardware (computerized)
     Instruments                 Important              Hardware (non-electronic)
                                                        Software
                                                        Pallet Layout
     Workspace                 Very Important           Utilization of Floor Space
                                                        Space Available
                                                        Dock Management
                                                        Package Labeling
 Process Management          Extremely Important
                                                        Documented Standard Operating Procedures
                                                        Metrics
Table 4. MU UPS Truck Crew Evaluation Dimensions, Importance Weighting, and Sub-dimensions


All the dimensions evaluated were process dimensions. The stakeholders had initially requested
an evaluation of outcomes such as speed and accuracy, but it was determined that since no
performance standards had ever been developed or measurement methods implemented,
there was no criteria against which to rate the UPS Truck Crew’s current level of performance.

The stakeholders’ schedules did not allow for a second group interview, so they submitted their
sub-dimension weighting as individuals. The different professional priorities and viewpoints of
the stakeholders were reflected in how differently they weighted some of the sub-dimensions.
As the evaluation team was unable to obtain a consensus on the importance of the sub-
dimensions, only the weighting for the dimensions was used to calculate the final ratings. The
sub-dimension weighting is included as Appendix F for reference.




                                                   14
Sub-Evaluations
6. Process Evaluations

The entire evaluation was conducted as a process evaluation, and examined three dimensions
of merit:
       Instruments
       Workspace
       Process Management


Instruments
Dimension Evaluation Question: How do the instruments in use by the UPS Truck Crew rate
when compared to industry best practices?
Data Sources: Interviews, observation, extant data
Overall Rating: Acceptable

The instruments dimension examined the tools in use by the UPS Truck Crew in the course of its
operations, and was divided into three sub-dimensions:
   1. Hardware (Computerized) – laptop computers, handheld barcode scanners
   2. Hardware (Non-Electronic) – forklifts, pallet jacks, conveyors, bins, and other equipment
   3. Software – proprietary warehouse inventory system which runs on the laptops and
       accepts data from the barcode scanner

An assessment rubric was created to compare the current state of the three sub-dimensions to
industry best practices. See Appendix A for the Instruments Assessment Rubric; the highlighted
text indicates the criteria which best describe the current state of Instruments used by the UPS
Truck Crew.

Workspace
Dimension Evaluation Question: How does the physical workspace in use by the UPS Truck
Crew rate when compared to industry best practices?
Data Sources: Interviews, observation, extant data
Overall Rating: Acceptable

The workplace dimension examined the physical workspace in use by the UPS Truck Crew in the
course of its operations, and was divided into three sub-dimensions:


                                              15
1. Pallet Layout – how pallets are placed on the floor space for efficient sorting
   2. Utilization of Floor Space
   3. Space Available

An assessment rubric was created to compare the current state of the three sub-dimensions to
industry best practices. See Appendix A for the Workspace Assessment Rubric; the highlighted
text indicates the criteria which best describe the current state of the Workspace as used by the
UPS Truck Crew. Although Workspace is considered “Acceptable” under current conditions,
there is no room for expansion under the current configuration should the volume of inbound
packages continue to increase.

Process Management
Dimension Evaluation Question: How does the process management in use by the UPS Truck
Crew rate when compared to industry best practices?
Data Sources: Interviews, observation, extant data
Overall Rating: Mediocre

The process management dimension examined the management of operating processes in use
by the UPS Truck Crew in the course of its operations, and was divided into four sub-
dimensions:
   1. Dock Management – scheduling of deliveries and commitment to unload times
   2. Package Labeling – external labeling on packages to indicate shipment type, package
       contents, and quantity of individual packages in shipment
   3. Documentation of Standard Operating Procedures (DSOP)
   4. Metrics – defined standards of performance against which actual performance can be
       measured

An assessment rubric was created to compare the current state of the four sub-dimensions to
industry best practices. See Appendix A for the Process Management Assessment Rubric; the
highlighted text indicates the criteria which best describe the current state of the Process
Management in use by the UPS Truck Crew.

Of the four sub-dimensions, Dock Management and Package Labeling were rated as “Standard
Practices”. The other sub-dimensions, DSOP and Metrics, were rated as “Poor Practices” as no
standard operating procedure or performance metrics exist for this workgroup.

See Appendix B for a summary of the sub-dimension ratings and the rationale for each.




                                               16
7. Exportability

The processes in the evaluand are specific to the workgroup. There are no innovative methods
in place which could be adapted for other MU departments. The processes in the evaluand are
specific to the workgroup, and the following aspects of the UPS Truck Crew and the evaluation
are valuable to other similar context.

The greatest strengths of the UPS Truck Crew are the camaraderie and cooperation among the
crew members and their loyalty to their long-time supervisor. This positive environment has
contributed to the low turnover in this unskilled position, thus maintaining a high level of
experience among the crew. Although the team chemistry encouraged by the UPS Truck Crew
Supervisor cannot itself be exported, the supervisor’s interactions with his team could be
studied to determine what elements of his supervisory style could help departments
experiencing high personnel turnover rates.

The evaluation team developed performance rubrics for the UPS Truck Crew based on
documented industry best practices. According to the Inbound Manager, no performance
rubrics or productivity standards are in place elsewhere in the receiving department.
Productivity is a major concern of not only MU but the warehousing industry in general. MU
must develop performance standards and measure performance outcomes to ensure that all
parts of the receiving operation function at optimal levels, which should lead to improved
warehouse productivity and continued revenue growth. To develop those standards, the
operations management at MU should consult industry associations such as WERC, the
Association for Operations Management, and the Council for Supply Chain Management
Professionals for information on benchmarking and best practices.




                                             17
Conclusions
8. Overall Significance
The purpose of this evaluation was to understand the receiving process’s current level of merit
and to identify what changes to the process or resources could improve its performance. The
results obtained from each dimension were calculated and summarized in Appendix G. The
overall results (shown in Table 5) of the evaluation revealed the receiving process’s current
overall level of merit as “Acceptable” when measured on a 5-level scale (Poor - Mediocre -
Acceptable - Very Good - Excellent).

                                                   Rating
   Overall
                                                       
  Evaluand


 Dimension                                                                             Weighting

 Instruments                                                                          Important
                                                                                          Very
 Workspace                                             
                                                                                       Important
  Process                                                                              Extremely
                                       
Management                                                                             Important
                      Poor         Mediocre       Acceptable   Very Good   Excellent


Table 5. Ratings for Overall Evaluand and Dimensions

The Instruments dimension was rated as "Acceptable" overall because the hardware and
software in use meet current needs, are properly maintained, and function correctly. All three
Instrument sub-dimensions were rated as “Standard Practices”; none are in critical need of
improvement to meet current needs, nor do any exceed industry standards.

The Workspace dimension was rated as “Acceptable” overall because under normal conditions
the floor space and layout is sufficient for the crew members to navigate easily between
locations. All three Workspace sub-dimensions were rated as “Standard Practices”; none are in
critical need of improvement to meet current needs, nor do any exceed industry standards.



                                                       18
The Process Management dimension was rated as “Mediocre” overall. The Dock Management
and Package Labeling sub-dimensions were both rated as “Standard Practices”. The DSOP and
Metrics sub-dimensions were rated as “Poor Practices”; neither standard operating procedures
nor any performance metrics or measurements exist for this workgroup. Although current
needs are being met by the processes in place, future needs will be negatively impacted by the
lack of documentation and metrics.

The dimensions’ strengths and weaknesses are shown in Table 6, in order of importance within
each dimension based on their potential level of impact on the evaluand.

  Dimension                    Strengths                          Weaknesses
Instruments         1.   Enough hardware to meet          1. Not enough equipment to
(Important)              current needs.                      meet future demands.
                    2.   Have the right tools to do       2. Pallet jacks are past or near
                         the job.                            the end of their life
                    3.   Hardware is easy to use and         expectancy.
                         in good repair.
                    4.   Software integrates with
                         next step in receiving
                         process.
Workspace           1.   Equipment is laid out to         1. No space to grow.
(Very                    maximize available floor         2. Lack of space causes choke-
Important)               space.                              points.
                    2.   Enough space to meet             3. Lack of space makes it
                         current needs during periods        difficult to walk during busy
                         of normal inbound volume.           periods.
                                                          4. During busy periods floor
                                                             space is very limited at best,
                                                             non-existent at times.
Process             1. A package labeling system          1. No metrics exist to measure
Management             exists and is used (although          performance of the truck
(Extremely             not always followed)                  crew or their suppliers.
Important)          2. UPS truck driver scheduled         2. No SOP exists to verify
                       to arrive early enough for            Standards, train new
                       unloading to be completed             employees, or pass on tacit
                       in a timely manner.                   knowledge.
                    3. Truck Crew is at work before       3. UPS truck driver may be late,
                       UPS Truck Driver shows up.            with no negative
                                                             consequences, impacting
                                                             schedule of UPS Truck Crew
                                                             and other receiving areas.



                                              19
Table 6. Strengths and Weaknesses of Evaluand Dimensions




                                                    20
9. Recommendations

Of the three dimensions evaluated in this project, Process Management was considered the
most important by the stakeholders (see Table 5 on page 17), but earned only a “Mediocre”
rating from the evaluation team. This dimension has the most opportunities for improvement in
the shortest amount of time, and at the lowest cost. Specific recommendations to improve this
dimension include:

   1. Develop a standardized product labeling system. Technology exists to develop a barcode
      that stores all shipment information and could update the system once scanned.
      Customers could be required to print this barcode and attach it to the box or invoice
      before shipment. The evaluation team understands that this step is already under
      consideration by MU, and recommends that it be implemented if feasible.
   2. Gather metrics to improve and manage the receiving process. By tracking metrics, the
      receiving department can take appropriate actions to drive continual process
      improvements. It is also good practice to report metrics to upper management and post
      results where they are accessible to the UPS Truck Crew.
   3. Document operating procedures as a way to standardize processes and terminology.
      This will ensure that tacit knowledge is not lost as part of a succession management
      plan, and will help provide consistent on-the-job training for new hires.

Workspace and Instruments both received an “Acceptable” rating. Although these dimensions
are less important than the process management dimension, both offer areas of opportunity
which can significantly improve the receiving process. These recommendations will require a
greater investment in monetary and time resources.

   1. Within the Workspace dimension, the floor space should be of critical interest. The
      Truck Crew is currently using its workspace to its full capacity. Because of the size and
      amount of equipment required to perform the job, workspace is limited. The limited
      workspace reduces the possible maximization of pallet and floor space usage due to a
      lack of space to place needed pallets, and creates choke points between an Express Belt
      and the Mechanical Roller. MU must seriously consider increasing floor space in
      preparation for future demand or face decreased productivity and bottlenecks.




                                             21
2. Within the Instruments dimension, the organization would need to update its
   computerized and non-electronic equipment as well as its software to meet increasing
   demands.
         Some hardware in use is near end-of-life, and will need to be replaced soon. All
         hardware should be inspected and evaluated for possible replacement or
         upgrades.
         MU should consider using hand-held computers with scanners rather than bulky
         laptops.
         Small packages are initiated by the UPS Truck Crew, and then the same data is
         entered again by Direct Receiving. It would be more efficient to have Direct
         Receiving initiate small packages so that the UPS Truck Crew can focus on large
         packages.




                                         22
Reporting
This evaluation report was created for the benefit of the evaluand stakeholders at MU:
   Director of Operations
   Operations Manager
   Inbound Manager
   UPS Truck Crew Supervisor

Evaluation team member Chester Stevenson will e-mail a brief summary of the evaluation
team’s conclusions and recommendations, plus a copy of the full report, to the four
stakeholders and to the Vice President of Human Resources at MU. The stakeholders may
share the information with other MU personnel as desired.

Any questions about the evaluation may be directed to team member Chester Stevenson.




                                              23
References
Brinkerhoff, R. O. (2006). Telling training’s story: Evaluation made simple, credible, and
       effective. San Francisco: Berrett-Koehler.

Davidson, E. J. (2005). Evaluation methodology basics: The nuts and bolts of sound evaluation.
       Thousand Oaks, CA: SAGE Publications.

Scriven, M. (1991). Evaluation thesaurus (4th ed.). Newbury Park, CA: SAGE Publications.

Scriven, M. (2007). Key evaluation checklist. Retrieved from
       http://www.wmich.edu/evalctr/checklists/kec_feb07.pdf

Vitasek, K., Harrity, C., O'Donoghue, K., & Symmes, S. (2007). Warehousing & fulfillment process
       benchmark & best practices guide. Retrieved from
       http://www.werc.org/assets/1/workflow_staging/Publications/701.PDF




                                                24
Appendix A: MU UPS Receiving Process Assessment Rubrics with Criteria Highlighting


 Dimension of      Sub-
                                                 Poor Practices                                Standard Practices                              Best Practices
    Merit       Dimension
                                       Hardware is out of date and limited in          Available hardware meets current needs.     Available hardware meets current and future
INSTRUMENTS                            quantity or not in an adequate quantity.                                                    needs.
                     Hardware                                                          Hardware is properly maintained and
                (Non-Electronic) -     Available hardware does not meet current        functional.                                 Backup equipment is available to replace out
 WEIGHTING:      includes forklifts,   needs.                                                                                      of service equipment.
                 pallets, shelving,
  Important       conveyors, bins      Hardware is out of repair or requires                                                       Hardware is efficient and does not add
                                       excessive service.                                                                          additional steps to work processes.

                                       Hardware is not mobile.                         Hardware is mobile.                         Hardware is highly mobile and compatible
                                                                                                                                   with the latest software.
                                       Hardware is out of date and not                 Hardware is compatible with newer
                                       compatible with newer software.                 software.                                   Available hardware meets current and future
                                                                                                                                   needs.
                                       Hardware is out of date and limited in          Available hardware meets current needs.
                    Hardware
                                       quantity or not in an adequate quantity.                                                    Backup equipment is available to replace out
                 (Computerized)
                                                                                       Hardware is properly maintained and         of service equipment.
                                       Available hardware does not meet current        functional.
                                       needs.                                                                                      Hardware is efficient and does not add
                                                                                                                                   additional steps to work processes.
                                       Hardware is out of repair or requires
                                       excessive service.
                                       Software is slow, not easy to understand,       Software can be learned within an           Software is easily understandable and easy to
                                       and not efficient.                              acceptable time period.                     use.

                                       Software does not interface with the next       Software interfaces with - and can be       Software is easily upgradeable and easily
                                       area in the receiving process.                  retrieved by other parts of the receiving   integrates with other company software.
                    Software                                                           process.
                                                                                                                                   Software provides metrics that can be
                                                                                       Software can be upgraded when               provided to customers.
                                                                                       requirements change.
                                                                                                                                   Software is updated regularly to support best
                                                                                                                                   practices.




                                                                                  25
Dimension of        Sub-
                                             Poor Practices                                 Standard Practices                                    Best Practices
   Merit         Dimension
                                   Pallet placement is not formalized               Pallets are laid out so that they do not hinder   Product placement is clearly defined.
 WORKSPACE
                                                                                    movement.
                                   Package placement is not clearly defined                                                           Sorting area is arranged to support demand
                                                                                    Package placement is clearly defined.             issues meeting current and future volume.
 WEIGHTING:                        Sorting area is not arranged to support
                  Pallet Layout
Very Important                     demand Issues meeting current volume.                                                              Pallets are laid out to optimize movement,
                                                                                                                                      and restrict fatigue or injury.
                                   Mobility around pallet area is difficult.


                                   Floor space is poorly laid out and mobility      Fixtures are placed so that they do not           Floor space is well laid out to support current
                                   is difficult.                                    hinder movement of product.                       and future demand.
                  Utilization of
                  Floor Space
                                   Poor layout in high traffic areas. Poor          Areas are laid out well to support current        Area is kept clean and clear of debris.
                                   housekeeping                                     demand.
                                   Floor space does not meet current needs.         Floor and storage space meets current             Floor and storage space is adequate to
                                                                                    needs.                                            accommodate current and future demand.
                                   There is not enough room to unload an
                                   entire truck during peak times.                  There is adequate space to unload a truck
                 Space Available
                                                                                    and still allow for mobility.
                                   Storage space is not adequate to hold
                                   overstock during peak times.                     Storage space is adequate to hold overstock
                                                                                    during peak times.




                                                                               26
Dimension of
               Sub-Dimension                    Poor Practices                             Standard Practices                                 Best Practices
   Merit
                                      Trailer deliveries not scheduled             Shipper given specified delivery window         Doc appointments are made and a
  Process
                                                                                                                                   commitment to unload every vehicle within
                Dock Management
Management                            Trailers not unloaded in a timely way        Timely unloading to avoid                       two hours when the appointment is kept,
                                                                                   detention/demurrage                             labor and dock space utilization is optimized
                                      No package labeling OR package               Not all packages labeled by suppliers, but is   Package is labeled by supplier, to
 Weighting:                           inconsistently or incorrectly labeled        labeled upon receipt                            specification receipt so check-in can be
                 Package Labeling                                                                                                  made with bar-code scan into the system
 Extremely
 Important     Documented Standard    No process documentation exists OR           Receiving processes are documented and          Receiving processes documented, made
                Operating Procedure   processes are written but not consistently   available but tacit knowledge is not made       readily available, and consistently followed
                      (DSOP)          followed or made available                   explicit

                                      Customer shipping errors are not tracked     Ad hoc process to track inbound receiving       Basic receiving requirements are outlined
                                      (e.g. % of packages                          errors or track internal functional metrics     and shared with all customers
                                      received without a invoice or % of
                                      packages received mislabeled)                Customer receiving errors are not shared        Formal process to collect inbound receiving
                                                                                   with customers                                  metrics and data is shared with customers
                                      No established
                                      performance                                  Basic receiving requirements are outlined and   Internal performance metrics are collected
                                      metrics or SLAs                              shared with all customers                       and posted or shared with employees
                                      (service level
                     Metrics
                                      agreements)                                   Formal process to collect Inbound receiving
                                      established with                             metrics, but data is not shared with
                                      suppliers                                    customers

                                      Internal performance
                                      indicators
                                      (e.g. dock to
                                      stock time) are
                                      not tracked




                                                                              27
Appendix B: Summary of Ratings with Rationale


 Dimension of
                   Sub-Dimension                    Rating                                                       Rationale
    Merit
                                                                          The criteria for non-electronic hardware all fall under the Standard Practices rating.
                  Hardware (Non-Electronic)     Standard Practices        According to one stakeholder, some of the existing hardware will require replacement in
                                                                          the near future but all equipment is currently adequate.
                                                                          The criteria for computer hardware all fall under the Standard Practices rating. The
 Instruments       Hardware (Computerized)      Standard Practices        laptops are not modern, but have sufficient capacity to run the necessary software.

                                                                          The criteria for software all fall under the Standard Practices rating. The software was
                           Software             Standard Practices        created in-house and continues to meet the organization’s needs.

                                                                          The criteria for pallet layout all fall under the Standard Practices rating. There is no
                         Pallet Layout          Standard Practices        consistent layout plan for pallets, but the crew members are successfully able to create
                                                                          the layout for daily conditions.
                                                                          The criteria for utilization of floor space all fall under the Standard Practices rating. Space
  Workspace        Utilization of Floor Space   Standard Practices        is limited, but the crew reports no significant problems in navigating the space under
                                                                          normal volume conditions.
                                                                          The criteria for space available all fall under the Standard Practices rating. The space does
                       Space Available          Standard Practices        accommodate current normal volume, but is less able to accommodate peak volume.
                                                                          There is no room for future expansion.
                                                                          The criteria for dock management all fall under the Standard Practices rating. The main
                      Dock Management           Standard Practices        issue with shipment delivery is related to the reliability of UPS delivery employees, which
                                                                          MU cannot control.
                                                                          The criteria for package labeling all fall under the Standard Practices rating. Current
                       Package Labeling         Standard Practices        package labeling is adequate, but MU is looking at ways to improve it.
   Process
 Management                                                               The criteria for DSOP fall under the Poor Practices rating. There is no documentation of
                Documented Standard Operating
                                                  Poor Practices          standard operating procedures. All knowledge is tacit and communicated verbally to new
                     Procedure (DSOP)
                                                                          employees.
                                                                          The criteria for metrics all fall under the Poor Practices rating. No performance metrics
                            Metrics               Poor Practices          exist, nor do any methods of measuring aspects of performance.




                                                                     28
Appendix C: Data Sources for Instrument Dimension

                                                                          Interviews
Sub-Dimension     Data Sources                                                                                                     Observation     Extant Data
                                                         Truck Crew                                    Supervisors
                 (1) Extant Data –    Q11: Can you think of one thing that you use now            Q: How long do the Pallet                      Equipment Inventory
                 Review equipment     (like a piece of equipment or a procedure) that             Jacks typically last before                    includes:
                 inventory.           prevents you from working faster or more                    they need to be replaced?
                 Review maintenance   accurately?                                                                                                Forklift (n=2)
                 records              a. No -TC #1                                                With the amount of use they                    Pallet Jack (n=4)
                                                                                                  get during our receiving                       Express Belt
Hardware (non-   (2) Interviews –     b. Not really offhand. Space is the biggest hindrance.      process, they typically have a                 w/computer (n=4)
                 Management (n=3)     TC #2                                                       lifecycle of 3 – 4 years. Two                  Roller (n=1)
  electronic)
                 and Crew (n=4).                                                                  of the Pallet Jacks have been                  Pallets
                                      c. Some of the belts aren’t that good for rolling boxes.    in use for 3 years, and two                    Bins (n=2)
                                      When these belts are extended, the rollers are too far      have been in use for 6 – 7
                                      apart and don’t roll boxes easily. TC #3                    years. Truck Crew
                                      d. Nothing that gets in my way. The other guys get in       Supervisor
                                      my way because of the limited space. TC #4
                 (1) Extant Data –    Q13: How would you improve the layout of your                                                              Computerized
                  Review equipment    work area?                                                                                                 Inventory includes:
                 inventory.           d. The racks are not very sturdy. TC #4
                  Review available                                                                                                               Computer with
   Hardware      hardware                                                                                                                        scanner (n=3)
                 specifications.
(Computerized)
                 (2) Interviews –
                 Management (n=3)
                 and Crew (n=4).
                 (1) Interviews -     Q7: How long does it take you to do the data entry          Q1: How long have you
                 Management (n=3),    for each package? How easy is it to use the software        been using the current
                 Crew (n=4),          to do the data entry? How easy is it to make                software?
                 Programmers (n=1).   corrections if you type something wrong?
                                                                                                  The software has been
   Software                           a. 15 sec - 1.5 min (depending on how many                  unchanged for the last 15
                                      packages) Labels without bar codes = does not add           years.
                                      significant extra time to initiation To edit data entry,
                                      search by invoice # and edit, very simple. Receiving
                                      cannot access this software - if they find an error, they
                                      bring it to the truck crew’s attention so the truck crew

                                                                              29
can make the correction. Can track which truck crew
member made the error, but not known if accuracy
problems are tracked and taken into account for
performance reviews -TC #1

b. 3-4 minutes at the longest. Very repetitive once
you learn the process should be quick (his time is
longer because he is new). Easy up to a point until
you get to the 2nd to last screen. Once it gets to that
point it would have to be corrected by supervisor -TC
#2

c. Not long, I just scan the barcode and UPS code
(these packages have standard UPS labels, I assume). I
have to open the packages occasionally to get a
packing list, but in most cases I just scan it. It’s easy to
make corrections. TC #3

d. Maybe 10 seconds, 20 seconds - I’ve been here 10
years so I can fly through it. The software is really easy
to use, and I can barely send an e-mail! Software is
not complex. Everybody has their own log-in, but not
everybody has editing permission. Supervisor and
unofficial assistant supervisor can make changes if
errors are found at the end of entry TC #4




                                           30
Appendix D: Data Sources for Workspace Dimension

                                                                           Interviews
Sub-Dimension     Data Sources                                                                                   Observation             Extant Data
                                                          Truck Crew                             Supervisors
                 (1) Interviews -       Q6: How easy is it to sort the large packages so that                  Pallets are laid out in
                 Management (n=3)       all the packages from one sender are together? Are                     rows but package layout
                 and Crew (n=4).        the labels consistent or do you run into problems                      is not standardized.
                                        with labels having different names for one sender?
                 (2) Observation -
                 Observe receiving      b. It’s fairly simple, my biggest problem was spending
                 process to determine   too much time trying to remember where I had put
                 product placement      things down, this became easier with practice.
                 trends.                Sometimes pallets are organized by #, other times by
                                        return/guide/etc - it depends on who sets up the
                                        pallets. TC#2

                                        Q13: How would you improve the layout of your
                                        work area?

                                        a. The racks used to run the opposite way, but that
                                        reduced the loading area so we changed the rack
 Pallet Layout                          orientation to give us more space. Racks are almost to
                                        the ceiling now, at max height for forklifts -TC#1



                                        b. A branching conveyor belt - pull off different
                                        categories-guides, returns, and others This would
                                        probably take up a lot of space, but would make it
                                        easier to sort and pallet. TC #2

                                        c. More space. Not sure offhand what would help the
                                        layout. (moving student returns to another part of the
                                        building - would require a different address and would
                                        only eliminate one roller) TC#3 d. Just expand,
                                        honestly. TC #4




                                                                                  31
(1) Interviews -         Q12: Is there anything about the physical layout of         There is a choke point
                  Management (n=3)         your warehouse area that gets in the way during             between the third
                  and Crew (n=4).          normal weeks? What about during high-volume                 Express Belt and the
                                           weeks?                                                      Roller.
                  (2) Observation -        a. High volumes SKUs that have no invoice (labeling),
                  Observe receiving        having to wade through many packets -TC#1                   Every open space is
                  process to determine                                                                 used, with narrow paths
 Utilization of   product placement        b. The track area coming from the belt to the student       to walk though.
                  trends and floor space   returns is a high-traffic area and is pretty tight for
 Floor Space
                  usage.                   space. (area around the first computer - the rack is
                                           close to the conveyor, causes a bottleneck). Takes
                                           more time because you have to detour with the
                                           forklift. TC #2

                                            c. In a normal week no, but yes during a busy week. TC
                                           #3
                  (1) Interviews -         Q6: How easy is it to sort the large packages so that       Every space is used.
                  Management (n=3)         all the packages from one sender are together? Are
                  and Crew (n=4).          the labels consistent or do you run into problems
                                           with labels having different names for one sender?
                  (2) Observation -          a. The larger the load the harder it is. Space makes it
                  Observe receiving area   hard (after you get so much you forget where you put
                  to determine space       it). Senders sometimes put the wrong information
                  availability.            (like name of individual rather than name of school) or
                                           no information (they don’t understand they are NOT
                                           the only vendor) -TC#1

                                           Q8: During normal times, is it easy to move the
Space Available                            packages around to where they need to go?
                                            a. Pretty easy but space is limiting -TC#1
                                           b. Yes - TC#2
                                           c. Pretty Easy TC # 3
                                           d. Normal times yes but space is also an issue during
                                           busy times. Freight (pallets) is bumping into other
                                           shipments.

                                           Q9: How does your work routine change during those
                                           weeks when the number of inbound packages is
                                           twice the usual volume?
                                           a. It’s a lot more fast pace. Where we’re rushed we
                                           are out of space quickly and it can be backed up for 5-

                                                                                      32
6 weeks. When outbound is busy, inbound personnel
are diverted there to help, which slows down the
inbound processes. -TC#1
b. Between freight coming off and coming in, space
becomes very tight, hard to move around with the
forklift because there’s stuff everywhere.-TC #2

c. Space (paraphrase) TC #3

Q10: Can you think of one thing that could be added
to your work area that would make your job easier?
 a. Space -TC#1

b. More space, definitely more space    TC#2

c. When I scan, wondering why it can’t be done about
the people that are checking it in. Seems like
initiation is redundant - why not just put student
returns in the bins and have the direct receiving group
do the check-in? Jerry and the rest of the crew are in
favor of this. This would both remove duplication of
effort and free up space that the student return rollers
currently take up. TC#3




                                          33
Appendix E: Data Sources for Process Management Dimension

Sub-dimension    Data Sources                                                                                                       Observation                Extant Data
                                                         Truck Crew                                   Supervisors
                (1) Interviews -       Q4: How much time is there between the time you                                            The UPS Truck is
                Management (n=3)       start work and the time the first UPS truck arrives?                                       available before the
                and Crew (n=4).        a. Anywhere from an hour to 1.5 hours, depending on                                        truck crew arrives.
                                       if we have the usual UPS driver. We come in at 7, the                                      However, it cannot be
                (2) Observation -      drivers don’t come in until 8:30 -TC#1                                                     unloaded until the
                Observe unloading                                                                                                 driver is ready.
                process and record     b. When they have the normal driver, he’s usually
                times to completion.   here about 8:30-9. When he was changing his job, the
                                       communication over at UPS was off - the driver would
                                       show up late, we would have to call UPS to find out
    Dock                               where the truck was. -TC #2
 Management
                                       c. Depends on driver (8:15-10am)..
                                       Sometimes there is packages left in receiving from
                                       the day before that they can unpack until the driver is
                                       there TC#3 The truck trailer gets there before we do
                                       (it’s driven over and left - the truck cab goes off on
                                       another job).

                                        d. The truck trailer gets there before we do (it’s
                                       driven over and left - the truck cab goes off on
                                       another job). TC#4.
                (1) Observation        Q6: How easy is it to sort the large packages so that     Weaknesses in receiving          Labels are colored,       No package labeling
                                       all the packages from one sender are together? Are        process                          depending on the type     documentation exists.
                (2) Interviews -       the labels consistent or do you run into problems         There are 7 to 9 different       of delivery.
                Management (n=3),      with labels having different names for one sender?        variations for any given ISBN                              No documentation exists
                Crew (n=4), and        a. Senders sometimes put the wrong information            (book sorted by type of          Customers do not          to inform customers of
   Package      Programmers (n=2).     (like name of individual rather than name of school)      edition and physical             always properly label     how to properly label a
                                       or no information (they don’t understand they are         condition). Returns may not      packages.                 package.
   Labeling                            NOT the only vendor) -TC#1                                be classified correctly by the
                                                                                                 store/buyback, or returns        Sometimes customers
                                       c. The count can sometimes be off but as long as the      received may not have            forget to put labels on
                                       labels are there. On the majority, the labels are there   originated at MBS in the         packages.
                                       -TC #3                                                    first place. Returns come in
                                                                                                 from stores, buyback             When customers ship

                                                                                 34
d. It’s pretty simple after doing it for so long. Store    contractors, and individuals     multiple packages, UPS
                                   numbers are written on the packages, so we get used        - labeling not consistent,       does not always deliver
                                   to looking for store numbers to match up shipments.        may not be accurate.             them in the same
                                   Labels are mostly consistent, but I have seen              Guaranteed buybacks pre-         shipment.
                                   packages with label but no information or that have        labeled for accuracy.
                                   just the sender’s first name and not the last, or boxes    Department would like to         Barcodes on the
                                   with no labels (it’s a sticky tag that may accidentally    look into more bar code          package label only
                                   get peeled off during shipment) -TC #4                     information. Right now the       include the UPS
                                                                                              receiving crew has to input      Shipping number.
                                                                                              much information manually.
                                                                                              Inconsistency in how             No customer education
                                                                                              bookstores label returns, so     process exists at any
                                                                                              receiving crew won’t have        level of the company
                                                                                              accurate information (so         to inform shippers of
                                                                                              billing for returns may be       proper procedures.
                                                                                              inaccurate because returns
                                                                                              from a given store may not
                                                                                              be processed as a group).-
                                                                                              Operations Manager
                                                                                              Problem with Invoicing of
                                                                                              shipments, improper
                                                                                              labeling, and improper
                                                                                              counts - weaknesses are on
                                                                                              the sender side. If sender
                                                                                              information is correct,
                                                                                              receiving goes like
                                                                                              clockwork. Biggest problem
                                                                                              is that improper
                                                                                              identification. Truck Crew
                                                                                              Supervisor
            (1) Extant Data -      Q3: When you first started, was there any part of          New hires should be                                        None Available
            Review receiving and   the unloading and check-in process that took a little      comfortable within a 2-3
Document    shipping process       more time to learn? How long did it take for you to        week time frame, by then
            documentation.         feel pretty comfortable doing your job?                    we’ll know if they can cut it.
Standard                            a. Took about a week to get comfortable with the          They receive OJT. Just the
Operating   (2) Interviews -       entire process (including the computer). TC #1             hands-on responsibility. Go
            Management (n=3)        b. It was all kind of new to me, so I learned one thing   through proper lifting
Procedure   and Crew (n=4).        at a time - there’s a lot to learn at once, so I had to    methods (safety training, I
 (DSOP)                            break it down. Had to learn the difference between         assume) . This (receiving
                                   what’s a return and what’s a guide. I’m used to having     process) is a new beast even
                                   written directions/ guidelines, but all instruction here   if you have dock experience.

                                                                             35
was verbal and each person had his own way of doing      Can be overwhelming even
                                 things. It would have helped if I had something to       with experience. The
                                 read that was standardized. Without that, I wasn’t       sorting is the hardest part of
                                 able to learn something until I actually needed to do    the learning curve. (labeling,
                                 it. I didn’t think any particular process was more       categorizing). The guys
                                 difficult to learn than another. I started at the        already do categorization on
                                 beginning of a buyback rush so I was thrown into it -    floor. Ebb and flow of
                                 learned the motions, wasn’t able to get more in-         volume would not really
                                 depth until rush was over. -TC# 2                        make a color coded floor
                                 c. Took about a week to get comfortable with the         labeling system feasible --
                                 entire process (including the computer). TC#3            Truck Crew Supervisor
                                  d. The unloading part. I’m not really computer savvy,
                                 but it’s easy to pick up. With unloading, had to learn
                                 the different shipment types. Took about two weeks
                                 tops to feel comfortable. TC #4
                                 Q14: If you were in charge, how would you improve
                                 the efficiency of the receiving process?
                                 a. I don’t know if there’s really any way to improve
                                 (the people). Nothing I can think of offhand. TC #1 b.
                                 When bringing someone in - I can pick up things
                                 quickly because of my training but it might be hard
                                 for others. I see it as a weeding out process to see
                                 who they want to keep, but it would help to have a
                                 truck crew-specific training manual and job aid.
                                 Documented SOP - there’s isn’t one now. For
                                 example, a standardized way of setting up the pallets.
                                 TC #2
                                 c. Current method is good as long as team works
                                 together. TC#3
                                 d. The number one thing is space, then the timing for
                                 UPS arrival - we get here at 7 but he doesn’t get here
                                 until later. TC #4
          (1) Extant Data -                                                               Setting benchmarks for           None Available
          Review receiving and                                                            future evaluations;
          shipping metric                                                                 establishing regular re-
          documentation.                                                                  assessments of receiving
Metrics                                                                                   processes; defining ideal
          (2) Interviews -                                                                performance for individuals;
          Management (n=3)                                                                defining ideal performance
          and Crew (n=4).                                                                 for the receiving team;
                                                                                          exporting elements of the

                                                                          36
receiving processes to other
     parts of the organization;
     and/or developing
     evaluation processes for
     other parts of the
     organization. -Operations
     Manager

     Would like to see more
     metrics [in receiving
     process} such as copies
     checked per hour, book
     shelved per hour no formal
     written documentation -
     Inbound Manager




37
Appendix F: Sub-dimension Weighting of Importance by Stakeholders


       Sub-Dimensions            Inbound Manager            Operations Manager     Truck Crew Manager
           Hardware
                                 Extremely Important             Important          Extremely Important
        (non-electronic)
    Hardware (Computerized)      Extremely Important             Important          Extremely Important

           Software                Very Important              Very Important         Very Important

         Pallet Layout               Important                   Important          Extremely Important
         Utilization of
                                 Extremely Important         Extremely Important    Extremely Important
         Floor Space
        Space Available          Extremely Important           Very Important       Extremely Important

       Dock Management           Extremely Important             Important          Extremely Important

        Package Labeling         Extremely Important           Very Important       Extremely Important
 Documented Standard Operating
                                     Important                   Important              Important
       Procedure (DSOP)
            Metrics              Extremely Important           Very Important           Important




                                                       38
Appendix G: Scoring Rubrics for MU UPS Receiving Process Evaluation
                 Rubric for Ranking Importance                                                Rubric for Ranking Sub-Dimensions
                                                                                                                 Standard
    Important          Very Important       Extremely Important                      Poor Practices                             Best Practices
                                                                                                                 Practices
       1                     2                        3                                    1                         2                3



                                                   Sum of Weighted Dimensions

                                                 Weighting Value                                    Sub-Dimension
     Dimension               Weighting                                   Sub-Dimension                                     SDR Value (R)   IxR
                                                       (I)                                           Rating (SDR)
                                                          1             Hardware      (non-         Standard Practices           2          2
                                                                            electronic)

   INSTRUMENTS               Important                                Hardware (Computerized)       Standard Practices           2          2
                                                          1

                                                          1                  Software               Standard Practices           2          2
                                                   Sum of Importance and Rating                                                             6

                                                          2                   Pallet Layout           Standard Practices         2          4

                                                                              Utilization of
    WORKSPACE              Very Important                 2                   Floor Space
                                                                                                      Standard Practices         2          4


                                                          2                 Space Available           Standard Practices         2          4

                                                   Sum of Importance and Rating                                                            12

                                                          3                Dock Management            Standard Practices         2          6


                                                          3                 Package Labeling          Standard Practices         2          6
                             Extremely
PROCESS MANAGEMENT
                             Important                                   Documented Standard
                                                          3            Operating Procedure (DSOP)
                                                                                                        Poor Practices           1          3

                                                          3                       Metrics               Poor Practices           1          3
                                                                       39
                                                   Sum of Importance and Rating                                                            18
                                             Total Sum of Weighted Dimensions                                                              36
Score Combinations for Dimension Rating

                       Dimension
                                     Lower (L)
Sub-Dimension          Weighting                             Poor (P)             Mediocre (M)           Acceptable (A)          Very Good (V)           Excellent (E)
                                     Boundary
                          (W)
                                                        Most sub-dimensions      Most sub-dimensions     Most sub-dimensions     Most sub-dimensions
                                                        receive a 1, and one     receive a 2, and one    receive a 2, and one    receive a 3, and one
                                   All sub-dimensions                                                                                                    All sub-dimensions
                                                           sub-dimension            sub-dimension           sub-dimension           sub-dimension
                                       received a 1                                                                                                           receive a 3
                                                        receives a 2 for each    receives a 1 for each   receives a 3 for each   receives a 2 for each
                                                             Dimension                Dimension               Dimension               Dimension

 Hardware (non-
                           1               1                     1                        1                       2                       2                      3
   electronic)
   Hardware
                           1               1                     1                        2                       2                       3                      3
 (Computerized)
     Software              1               1                     2                        2                       3                       3                      3

   Pallet Layout           2               2                     1                        1                       2                       2                      3
Utilization of Floor
                           2               2                     1                        2                       2                       3                      3
       Space
 Space Available           2               2                     2                        2                       3                       3                      3

Dock Management            3               3                     1                        1                       2                       2                      3
 Package Labeling          3               3                     1                        2                       2                       3                      3
       DSOP                3               3                     1                        2                       2                       3                      3
     Metrics               3               3                     2                        2                       3                       3                      3




                                                                                40
IPT 530-EDubose evaluation methodology team project
IPT 530-EDubose evaluation methodology team project
IPT 530-EDubose evaluation methodology team project
IPT 530-EDubose evaluation methodology team project
IPT 530-EDubose evaluation methodology team project
IPT 530-EDubose evaluation methodology team project
IPT 530-EDubose evaluation methodology team project
IPT 530-EDubose evaluation methodology team project

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IPT 530-EDubose evaluation methodology team project

  • 1. Merchandise Unlimited UPS Truck Crew Process Evaluation Final Report Evaluation Team: Eboni DuBose, Perri Kennedy, and Chester Stevenson IPT 530 Evaluation Methodology Boise State University Spring 2011
  • 2. Table of Contents Preliminaries ................................................................................................................................... 2 I. Executive Summary .................................................................................................................. 2 II. Preface ..................................................................................................................................... 4 III. Methodology .......................................................................................................................... 5 Foundations .................................................................................................................................... 6 1. Background and Context ......................................................................................................... 6 2. Descriptions and Definitions ................................................................................................... 7 3. Stakeholders .......................................................................................................................... 12 4. Resources .............................................................................................................................. 12 5. Dimensions of Merit and Importance Weighting ................................................................. 14 Sub-Evaluations............................................................................................................................. 15 6. Process Evaluations ............................................................................................................... 15 7. Exportability .......................................................................................................................... 17 Conclusions ................................................................................................................................... 18 8. Overall Significance ............................................................................................................... 18 9. Recommendations ................................................................................................................ 21 Reporting ................................................................................................................................... 23 References .................................................................................................................................... 24 Appendix A: MU UPS Receiving Process Assessment Rubrics with Criteria Highlighting ............. 25 Appendix B: Summary of Ratings with Rationale ......................................................................... 28 Appendix C: Data Sources for Instrument Dimension .................................................................. 29 Appendix D: Data Sources for Workspace Dimension .................................................................. 31 Appendix E: Data Sources for Process Management Dimension ................................................. 34 Appendix F: Sub-dimension Weighting of Importance by Stakeholders ...................................... 38 Appendix G: Scoring Rubrics for MU UPS Receiving Process Evaluation ..................................... 39 1
  • 3. Preliminaries I. Executive Summary Introduction Merchandise Unlimited (MU, pseudonym), a merchandise distribution company based in the Midwestern region of the United States, had not examined the processes and resources in place to receive inbound shipments for at least a decade. The Director of Operations and the Operations Manager requested a formative evaluation to both establish how well the inbound receiving process (hereinafter referred to as “evaluand.”)should function and discover how well it actually does function. In the spring of 2011, three graduate students (hereinafter referred to as “evaluation team”) from Boise State University’s Instructional & Performance Technology program were asked to conduct an evaluation of the inbound receiving process. The stakeholders asked for the evaluation team to look specifically at the 10-person truck crew (hereinafter referred to as “UPS Truck Crew”) which offloads and sorts inbound shipments of used and returned merchandise which were delivered via the United Parcel Service (UPS). The evaluation team created assessment rubrics based on industry best practices and the needs of MU, and then examined the practices and resources in place. Methodology The evaluation team conducted a formative goal-based evaluation structured on Scriven’s (2007) Key Evaluation Checklist. It was designed to examine the current state of the UPS receiving process and how it could be improved. After discussions with the stakeholders, the evaluation team focused on three dimensions: Instruments Workspace Process Management Each dimension was weighted based on the stakeholders’ consensus determination of its importance (Important, Very Important, or Extremely Important). The evaluation team created an assessment rubric based on warehousing best practices, and then compared the current processes and resources in use by the UPS Truck Crew to the assessment rubric. Conclusions Using a 5-point scale (Poor, Mediocre, Acceptable, Very Good, and Excellent), the overall quality of the UPS receiving process is rated “Acceptable” for current organizational needs. However, the evaluation team concluded that the current set of processes and resources may not be sufficient to handle future needs. A major concern is that Process Management, weighted as Extremely Important by the stakeholders, was rated as “Mediocre” when 2
  • 4. compared to industry best practices. The overall evaluand rating and dimensions with ratings and weighting are shown in Table 1. Rating Overall  Evaluand Dimension Weighting Instruments  Important Very Workspace  Important Process Extremely  Management Important Poor Mediocre Acceptable Very Good Excellent Table 1. MU UPS Truck Crew Receiving Process Evaluation Results Strengths Based on the evidence gathered, the evaluation team noted the following strengths of the UPS receiving process: Equipment in use is well maintained and sufficient to maintain current operation levels. Space is utilized as well as possible given its limitations. The supervisor and members of the UPS Truck Crew are capable, experienced, and work together as a cohesiveness unit. Opportunities for Improvement Based on the evidence gathered, the evaluation team made the following recommendations to the stakeholders: Develop and document a standardized operating procedure to ensure that tacit knowledge is not lost and that new hires receive consistent on-the-job training. Develop performance metrics to drive continual process improvements. Develop a standardized package labeling system for use by retail and individual customers. Examine all options for increasing floor space. Evaluate existing hardware for possible replacement or upgrades to meet future needs. Look into a possible redundancy in the initiation process, and consider the options for having initiation performed at the next stage of the receiving process. 3
  • 5. II. Preface Background Merchandise Unlimited, a merchandise distribution company based in the Midwestern region of the United States, had substantially upgraded and modernized much of its warehouse operations in recent years. However, the processes and resources in place to receive inbound shipments had not been updated or even examined for at least a decade. In January 2011, the Director of Operations and the Operations Manager of Merchandise Unlimited requested an evaluation of the processes in use by the receiving department, which handles all inbound shipments delivered to the company’s warehouse. Although other warehouse processes had been assessed and improved, the receiving functions had not been evaluated for many years. The stakeholders asked for the evaluation to look specifically at the receiving process conducted by the UPS Truck Crew, a 10-person workgroup which handles overstock and used merchandise shipped back, via UPS, to MU in individual non-palletized packages. The volume of shipments handled by this crew ranges from 1,500 to 3,500 packages each working day. The Director of Operations and the Operations Manager stated that they planned to adopt any recommendations which, in their judgment, will be both feasible and cost-effective to implement within the next two years. Evaluation Focus This evaluation examined the merit of the UPS receiving process. The Director of Operations and the Operations Manager wanted to assess the intrinsic quality of the UPS receiving process and see how it compared to industry best practices. The purpose of the evaluation was to develop the definition of merit for the receiving process, as the company had never established any benchmarks or ideals of performance. Evaluation Type This project was developed as a formative evaluation, as the stakeholders wanted to understand the current level of performance and what changes to the process or environment could improve that performance. Formative evaluation is defined as one “typically conducted during the development or improvement of a program… and it is conducted, often more than once, for the in-house staff of the program with the intent to improve” (Scriven, 1991, pp. 168- 169). Audience This evaluation report was created for the Director of Operations, the Operations Manager, the Inbound Manager, the UPS Truck Crew Supervisor, and the Vice President of Human Resources. 4
  • 6. III. Methodology Evaluation Approach When the evaluation project was proposed, the stakeholders had a general goal of improving efficiency in the UPS receiving process; they defined efficiency as the speed, accuracy, and cost- effectiveness of the overall process. However, no performance targets or ideals for the receiving department had ever been defined nor was any system in place to measure speed, accuracy or cost-effectiveness. Without any existing metrics against which to compare current performance, it was impossible to determine efficiency based on the stakeholders’ definition. After discussing this with the stakeholders, the evaluation team agreed to instead develop an assessment rubric based on industry best practices and then evaluate how the UPS receiving process compared to those best practices. The evaluation framework was based on Scriven’s (2007) Key Evaluation Checklist (KEC), which outlined a systemic examination of both processes and outcomes. Due to the lack of existing metrics, this evaluation was conducted strictly as a process evaluation which would examine the procedures and resources currently in use by the UPS Truck Crew. The methodology used was a goal-based dimensional evaluation of the evaluand’s absolute merit, in that the evaluation team identified dimensions of merit for the evaluand and then examined how the procedures and resources utilized in each dimension compared to the best practices defined in the assessment rubric. To develop the assessment rubric, the evaluation team researched best practices for warehouse receiving departments to determine ideal processes and identify key issues to examine. The evaluation team also documented the current procedures and environment in place to look for strengths and weaknesses in actual practice. The evaluation team developed its assessment rubric based on industry best practices compiled by Supply Chain Visions and sponsored by the Warehousing Education and Research Council (WERC). The evaluation team then hosted a focus group with the Operations Manager, Inbound Manager, and the UPS Truck Crew Supervisor to discuss the key elements of warehousing best practices. Some proposed dimensions were eliminated as not relevant or not of sufficient importance. The remaining dimensions were then shaped into a set of assessment rubrics which the evaluation team used to identify the areas of greatest opportunity for improvement. The process assessment rubrics are included as Appendix A. Data Collection Methods The evaluation team used a combination of data collection methods including interviews, extant data, and observation. Specific methods used for each dimension of merit are identified in Appendix C (Instruments), Appendix D (Workspace), and Appendix E (Process Management). 5
  • 7. Foundations 1. Background and Context Merchandise Unlimited (MU) is a merchandise distribution company based in the Midwestern region of the United States. MU has been in business in different incarnations for about a century, and has existed in its current form for nearly four decades. Its primary objective is to collect and distribute new and used products and ship them to its customers at the lowest cost possible. MU’s single warehouse is in operation 24 hours a day, five days a week to receive, sort, and distribute more than 20 million pieces of merchandise each year to both individual consumers and the company’s 2,500+ retail clients. For many years, the primary concern of warehouse management has been how fast products are shipped to the company’s customers, so almost all efforts at efficiency and modernization have been focused on this area. The current sorting and distribution areas of the warehouse make extensive use of modern technology, including robotics and 3-D scanning, to ensure that products are shipped accurately and rapidly. Management has recently turned its focus on how fast products are brought into the building, a process that has not been re-evaluated in over a decade. Out of all the products received in the warehouse, approximately 75% are delivered by a single carrier, UPS. The operations department would like to evaluate the existing UPS receiving process to improve inefficiencies and reduce costs. The stakeholders asked the evaluation team to conduct the first evaluation by focusing on the 10-person workgroup (the UPS Truck Crew) which handles offloading, sorting, and initiating individual packages of overstock and used merchandise shipped to the warehouse via UPS; this crew does not handle packages sent through other carriers, nor does it handle palletized loads. This merchandise includes both retail store overstock and returns from individual customers. The packages are classified by the UPS Truck Crew as large or small. Large packages: Shipments from retail customers Small packages: Shipments from individual customers, or internal mail Constraints Seasonal Fluctuations Due to the nature of its business, MU experiences predictable and significant seasonal fluctuations in both shipping and receiving merchandise through its warehouse. During normal 6
  • 8. times, the UPS Truck Crew may offload and sort 1,000-1,500 packages daily, most of which are picked up by the receiving departments that same day. During seasonal peak times, the crew may process as many as 3,500 packages daily; since the receiving departments cannot handle this inbound volume immediately, the UPS Truck Crew must store the packages for later pickup. Warehouse Space The UPS Truck Crew’s assigned space was sufficient a decade ago, when the average daily volume was approximately 800 packages. However, the average daily volume of packages has nearly doubled since that time. No additional floor space is available for the crew’s use. The storage area’s shelves are permanent fixtures which cannot be reconfigured or removed. 2. Descriptions and Definitions Evaluand Description The receiving department is broken into four sections: Truck crews, including the UPS Truck Crew, which unload the inbound shipments Receiving, which receives large packages from the truck crews Direct Receiving, which receives small packages from the truck crews Internal Mail, which receives small packages from the truck crews The UPS receiving process begins when the UPS truck driver unloads packages from his or her trailer onto a mechanical roller, which rolls the packages into the building. As each package comes down the roller, a member of the UPS Truck Crew removes it from the roller and examines its label. Large packages which are part of a shipment of three or more boxes are sorted directly onto pallets and then initiated. One- or two-box shipments of large packages are put on the express belts, initiated, and then sorted onto pallets. All small packages are put on the express belts, initiated, and then sorted into bins. Large package pallets are picked up by Receiving, and small package bins are picked up by Direct Receiving or Internal Mail. During the initiation process, a crew member enters a package’s shipping information into the warehouse inventory software using a laptop computer. Most package labels include UPS barcodes, which are scanned using a USB device that feeds a limited amount of package information into the warehouse inventory software; the crew member must initiate the rest of the information into the system. During times of normal inbound volume, the pallets and bins are picked up promptly by the destination department. 7
  • 9. When inbound volume is very high, the UPS Truck Crew moves the pallets into the storage area, where they may remain for up to two weeks awaiting pickup. A visual representation of this process is shown in Figure 1. Packages unloaded by UPS employee from trailer onto mechanical roller Packages removed from mechanical roller by UPS Truck Crew Packages sorted by type and placed on wooden pallets (Receiving) or onto express belts (Direct Receiving and Internal Mail) Packages initiated into inventory system using laptop computer and handheld scanner Normal receiving volume: Peak receiving volume: Pallets (Receiving) and bins (Direct Pallets and bins stored on shelving for Receiving and Internal Mail) prepared for later pickup immediate pickup Pallets and bins picked up by Receiving, Direct Receiving, and Internal Mail employees Figure 1. MU UPS Truck Crew Receiving Process. 8
  • 10. Process Logic Model The MU UPS Truck Crew Process Logic Model (see Figure 2) describes the factors and crew activities involved in the UPS receiving process, what activities the evaluation team performed in examining the process, and the intended results of the evaluation and subsequent changes to the process. Figure 2. MU UPS Truck Crew Receiving Process Logic Model 9
  • 11. Definitions Table 2 defines terminology used in this report, including evaluation concepts and terms used by MU for elements involved in the receiving departments. Absolute Merit The quality or value of something in absolute terms measured against a defined standard. Assessment Rubric A tool which provides an evaluative description of what performance looks like at each of two or more defined levels. Dimension of Merit Criteria of merit. These are aspects of an evaluand that define whether it is good or bad and whether it is valuable or not. Dimensional Evaluation An analytical evaluation in which the quality of the evaluand is determined by looking at its performance on multiple dimensions (criteria) of merit. Direct Receiving The division of the receiving department which opens small packages and sorts their contents for processing. Downstream Impactees Impactees that are not directly affected by the evaluand. Evaluand That which is being evaluated (e.g., program, policy, project, product, service, organization). Express Belt A 10-ft long mechanical roller with a computer and scanner at the end, used to initiate individual packages. Formative Evaluation An evaluation conducted for the purpose of improving a currently operational evaluand for the purpose of making improvements. Goal-based Evaluation A type of evaluation based on the goals of the evaluand. Inbound Shipments coming into the warehouse from outside vendors or customers. Initiating MU terminology for the process of entering package data into the warehouse inventory software. Internal Mail Packages received which are not return merchandise. These packages are given to the company’s internal mail facility, which delivers them to the appropriate recipients. 10
  • 12. Mechanical Roller A non-electrical device consisting of a series of rollers which is used to transport boxes from one area to another. Merit Intrinsic value, quality or significance of the evaluand. Overstock Excess merchandise in a store’s inventory, which may be returned to the vendor. Package Refers to a box, carton, or other shipping container received. They are typically referred to at MU as small or large depending on their actual size. Palletize To load packages onto wooden pallets for transportation or storage. Primary Consumers Actual or potential users of the evaluand. Program Logic Model A diagram that illustrates the cause-and- effect relationships between resources and activities, and the outcomes and impacts of the program. Truck Crew A crew of MU employees which sorts merchandise as it is unloaded from a truck into the warehouse. UPS Receiving Process Refers to the operations involved in unloading, sorting, and initiating inbound packages. UPS Truck Crew The 10-person truck crew which processes shipments of overstocks and used merchandise delivered by UPS to the warehouse. The UPS Truck Crew is the primary consumer of this evaluand. Upstream Stakeholders Stakeholders who are involved in the development, implementation, or management of the evaluand. Weight The determination of which evaluation criteria are the most important. Table 2. Definitions of Evaluation and MU Terminology 11
  • 13. 3. Stakeholders This evaluation was concerned with three sets of stakeholders: upstream stakeholders, primary consumers, and downstream impactees. The stakeholders are listed in Table 3. Upstream Stakeholders Primary Consumers Downstream Impactees Director of Operations UPS Truck Crew (n = 10) Immediate Impact Direct Receiving staff Operations Manager Receiving staff Internal Mail staff Inbound Manager Secondary Impact UPS Truck Crew Supervisor Product stockers Product shippers Distant Impact External customers Clients of external customers Table 3. MU Stakeholders for the UPS Truck Crew Evaluation. 4. Resources Financial Resources The UPS Truck Crew is funded by the organization as part of its Operations division. They receive whatever funding necessary to perform their required tasks. The upstream stakeholders stated that they are willing to spend money on changes which they deem likely to increase efficiency and/or decrease operating costs. The stakeholders will not reduce costs through staff reductions; if increased efficiency allows for a smaller UPS Truck Crew, extra crew members will be moved to other parts of Operations rather than be dismissed. Physical Resources See Figure 3 for a simplified illustration of the physical layout. The storage area assigned to the UPS Truck Crew is capable of holding between 65,000 and 75,000 packages on its shelving units. The storage shelves are permanent fixtures which cannot be removed or reconfigured. 12
  • 14. Figure 3. Layout of MU UPS Truck Crew Receiving Space Knowledge Resources The supervisor of the UPS Truck Crew has held this position for 15 years, and five of the ten crew members have worked there for five or more years. Turnover is modest and not considered by management to be an issue; morale within the crew appeared to be excellent. New hires receive on-the-job training in sorting and initiating packages. Technological Resources The UPS Truck Crew inputs data from each package label into a laptop computer running proprietary inventory management software. The software has a command-line interface. It takes an experienced crew member approximately one minute to type in the data for each individual package. The laptops in use are old and slow. The shipping labels on some packages include barcodes, which are scanned using devices which connect to the laptops via a USB cable. Data incorporated into the barcode is automatically entered into the inventory management software, but additional data must still be entered manually. 13
  • 15. 5. Dimensions of Merit and Importance Weighting The evaluation team met several times with the Operations Manager, Inbound Manager, and UPS Truck Crew Supervisor to refine the focus of the evaluation. When the final dimensions of merit were selected, the evaluation team conducted a group interview with these three upstream stakeholders so they could weigh the importance of each dimension using a 3-level scale (extremely important, very important and important). The evaluation team then divided each dimension into sub-dimensions, around which it created an assessment rubric. The dimensions, weighting, and sub-dimensions are shown in Table 4. Dimension of Merit Dimension Weighting Sub-dimension Hardware (computerized) Instruments Important Hardware (non-electronic) Software Pallet Layout Workspace Very Important Utilization of Floor Space Space Available Dock Management Package Labeling Process Management Extremely Important Documented Standard Operating Procedures Metrics Table 4. MU UPS Truck Crew Evaluation Dimensions, Importance Weighting, and Sub-dimensions All the dimensions evaluated were process dimensions. The stakeholders had initially requested an evaluation of outcomes such as speed and accuracy, but it was determined that since no performance standards had ever been developed or measurement methods implemented, there was no criteria against which to rate the UPS Truck Crew’s current level of performance. The stakeholders’ schedules did not allow for a second group interview, so they submitted their sub-dimension weighting as individuals. The different professional priorities and viewpoints of the stakeholders were reflected in how differently they weighted some of the sub-dimensions. As the evaluation team was unable to obtain a consensus on the importance of the sub- dimensions, only the weighting for the dimensions was used to calculate the final ratings. The sub-dimension weighting is included as Appendix F for reference. 14
  • 16. Sub-Evaluations 6. Process Evaluations The entire evaluation was conducted as a process evaluation, and examined three dimensions of merit: Instruments Workspace Process Management Instruments Dimension Evaluation Question: How do the instruments in use by the UPS Truck Crew rate when compared to industry best practices? Data Sources: Interviews, observation, extant data Overall Rating: Acceptable The instruments dimension examined the tools in use by the UPS Truck Crew in the course of its operations, and was divided into three sub-dimensions: 1. Hardware (Computerized) – laptop computers, handheld barcode scanners 2. Hardware (Non-Electronic) – forklifts, pallet jacks, conveyors, bins, and other equipment 3. Software – proprietary warehouse inventory system which runs on the laptops and accepts data from the barcode scanner An assessment rubric was created to compare the current state of the three sub-dimensions to industry best practices. See Appendix A for the Instruments Assessment Rubric; the highlighted text indicates the criteria which best describe the current state of Instruments used by the UPS Truck Crew. Workspace Dimension Evaluation Question: How does the physical workspace in use by the UPS Truck Crew rate when compared to industry best practices? Data Sources: Interviews, observation, extant data Overall Rating: Acceptable The workplace dimension examined the physical workspace in use by the UPS Truck Crew in the course of its operations, and was divided into three sub-dimensions: 15
  • 17. 1. Pallet Layout – how pallets are placed on the floor space for efficient sorting 2. Utilization of Floor Space 3. Space Available An assessment rubric was created to compare the current state of the three sub-dimensions to industry best practices. See Appendix A for the Workspace Assessment Rubric; the highlighted text indicates the criteria which best describe the current state of the Workspace as used by the UPS Truck Crew. Although Workspace is considered “Acceptable” under current conditions, there is no room for expansion under the current configuration should the volume of inbound packages continue to increase. Process Management Dimension Evaluation Question: How does the process management in use by the UPS Truck Crew rate when compared to industry best practices? Data Sources: Interviews, observation, extant data Overall Rating: Mediocre The process management dimension examined the management of operating processes in use by the UPS Truck Crew in the course of its operations, and was divided into four sub- dimensions: 1. Dock Management – scheduling of deliveries and commitment to unload times 2. Package Labeling – external labeling on packages to indicate shipment type, package contents, and quantity of individual packages in shipment 3. Documentation of Standard Operating Procedures (DSOP) 4. Metrics – defined standards of performance against which actual performance can be measured An assessment rubric was created to compare the current state of the four sub-dimensions to industry best practices. See Appendix A for the Process Management Assessment Rubric; the highlighted text indicates the criteria which best describe the current state of the Process Management in use by the UPS Truck Crew. Of the four sub-dimensions, Dock Management and Package Labeling were rated as “Standard Practices”. The other sub-dimensions, DSOP and Metrics, were rated as “Poor Practices” as no standard operating procedure or performance metrics exist for this workgroup. See Appendix B for a summary of the sub-dimension ratings and the rationale for each. 16
  • 18. 7. Exportability The processes in the evaluand are specific to the workgroup. There are no innovative methods in place which could be adapted for other MU departments. The processes in the evaluand are specific to the workgroup, and the following aspects of the UPS Truck Crew and the evaluation are valuable to other similar context. The greatest strengths of the UPS Truck Crew are the camaraderie and cooperation among the crew members and their loyalty to their long-time supervisor. This positive environment has contributed to the low turnover in this unskilled position, thus maintaining a high level of experience among the crew. Although the team chemistry encouraged by the UPS Truck Crew Supervisor cannot itself be exported, the supervisor’s interactions with his team could be studied to determine what elements of his supervisory style could help departments experiencing high personnel turnover rates. The evaluation team developed performance rubrics for the UPS Truck Crew based on documented industry best practices. According to the Inbound Manager, no performance rubrics or productivity standards are in place elsewhere in the receiving department. Productivity is a major concern of not only MU but the warehousing industry in general. MU must develop performance standards and measure performance outcomes to ensure that all parts of the receiving operation function at optimal levels, which should lead to improved warehouse productivity and continued revenue growth. To develop those standards, the operations management at MU should consult industry associations such as WERC, the Association for Operations Management, and the Council for Supply Chain Management Professionals for information on benchmarking and best practices. 17
  • 19. Conclusions 8. Overall Significance The purpose of this evaluation was to understand the receiving process’s current level of merit and to identify what changes to the process or resources could improve its performance. The results obtained from each dimension were calculated and summarized in Appendix G. The overall results (shown in Table 5) of the evaluation revealed the receiving process’s current overall level of merit as “Acceptable” when measured on a 5-level scale (Poor - Mediocre - Acceptable - Very Good - Excellent). Rating Overall  Evaluand Dimension Weighting Instruments  Important Very Workspace  Important Process Extremely  Management Important Poor Mediocre Acceptable Very Good Excellent Table 5. Ratings for Overall Evaluand and Dimensions The Instruments dimension was rated as "Acceptable" overall because the hardware and software in use meet current needs, are properly maintained, and function correctly. All three Instrument sub-dimensions were rated as “Standard Practices”; none are in critical need of improvement to meet current needs, nor do any exceed industry standards. The Workspace dimension was rated as “Acceptable” overall because under normal conditions the floor space and layout is sufficient for the crew members to navigate easily between locations. All three Workspace sub-dimensions were rated as “Standard Practices”; none are in critical need of improvement to meet current needs, nor do any exceed industry standards. 18
  • 20. The Process Management dimension was rated as “Mediocre” overall. The Dock Management and Package Labeling sub-dimensions were both rated as “Standard Practices”. The DSOP and Metrics sub-dimensions were rated as “Poor Practices”; neither standard operating procedures nor any performance metrics or measurements exist for this workgroup. Although current needs are being met by the processes in place, future needs will be negatively impacted by the lack of documentation and metrics. The dimensions’ strengths and weaknesses are shown in Table 6, in order of importance within each dimension based on their potential level of impact on the evaluand. Dimension Strengths Weaknesses Instruments 1. Enough hardware to meet 1. Not enough equipment to (Important) current needs. meet future demands. 2. Have the right tools to do 2. Pallet jacks are past or near the job. the end of their life 3. Hardware is easy to use and expectancy. in good repair. 4. Software integrates with next step in receiving process. Workspace 1. Equipment is laid out to 1. No space to grow. (Very maximize available floor 2. Lack of space causes choke- Important) space. points. 2. Enough space to meet 3. Lack of space makes it current needs during periods difficult to walk during busy of normal inbound volume. periods. 4. During busy periods floor space is very limited at best, non-existent at times. Process 1. A package labeling system 1. No metrics exist to measure Management exists and is used (although performance of the truck (Extremely not always followed) crew or their suppliers. Important) 2. UPS truck driver scheduled 2. No SOP exists to verify to arrive early enough for Standards, train new unloading to be completed employees, or pass on tacit in a timely manner. knowledge. 3. Truck Crew is at work before 3. UPS truck driver may be late, UPS Truck Driver shows up. with no negative consequences, impacting schedule of UPS Truck Crew and other receiving areas. 19
  • 21. Table 6. Strengths and Weaknesses of Evaluand Dimensions 20
  • 22. 9. Recommendations Of the three dimensions evaluated in this project, Process Management was considered the most important by the stakeholders (see Table 5 on page 17), but earned only a “Mediocre” rating from the evaluation team. This dimension has the most opportunities for improvement in the shortest amount of time, and at the lowest cost. Specific recommendations to improve this dimension include: 1. Develop a standardized product labeling system. Technology exists to develop a barcode that stores all shipment information and could update the system once scanned. Customers could be required to print this barcode and attach it to the box or invoice before shipment. The evaluation team understands that this step is already under consideration by MU, and recommends that it be implemented if feasible. 2. Gather metrics to improve and manage the receiving process. By tracking metrics, the receiving department can take appropriate actions to drive continual process improvements. It is also good practice to report metrics to upper management and post results where they are accessible to the UPS Truck Crew. 3. Document operating procedures as a way to standardize processes and terminology. This will ensure that tacit knowledge is not lost as part of a succession management plan, and will help provide consistent on-the-job training for new hires. Workspace and Instruments both received an “Acceptable” rating. Although these dimensions are less important than the process management dimension, both offer areas of opportunity which can significantly improve the receiving process. These recommendations will require a greater investment in monetary and time resources. 1. Within the Workspace dimension, the floor space should be of critical interest. The Truck Crew is currently using its workspace to its full capacity. Because of the size and amount of equipment required to perform the job, workspace is limited. The limited workspace reduces the possible maximization of pallet and floor space usage due to a lack of space to place needed pallets, and creates choke points between an Express Belt and the Mechanical Roller. MU must seriously consider increasing floor space in preparation for future demand or face decreased productivity and bottlenecks. 21
  • 23. 2. Within the Instruments dimension, the organization would need to update its computerized and non-electronic equipment as well as its software to meet increasing demands. Some hardware in use is near end-of-life, and will need to be replaced soon. All hardware should be inspected and evaluated for possible replacement or upgrades. MU should consider using hand-held computers with scanners rather than bulky laptops. Small packages are initiated by the UPS Truck Crew, and then the same data is entered again by Direct Receiving. It would be more efficient to have Direct Receiving initiate small packages so that the UPS Truck Crew can focus on large packages. 22
  • 24. Reporting This evaluation report was created for the benefit of the evaluand stakeholders at MU: Director of Operations Operations Manager Inbound Manager UPS Truck Crew Supervisor Evaluation team member Chester Stevenson will e-mail a brief summary of the evaluation team’s conclusions and recommendations, plus a copy of the full report, to the four stakeholders and to the Vice President of Human Resources at MU. The stakeholders may share the information with other MU personnel as desired. Any questions about the evaluation may be directed to team member Chester Stevenson. 23
  • 25. References Brinkerhoff, R. O. (2006). Telling training’s story: Evaluation made simple, credible, and effective. San Francisco: Berrett-Koehler. Davidson, E. J. (2005). Evaluation methodology basics: The nuts and bolts of sound evaluation. Thousand Oaks, CA: SAGE Publications. Scriven, M. (1991). Evaluation thesaurus (4th ed.). Newbury Park, CA: SAGE Publications. Scriven, M. (2007). Key evaluation checklist. Retrieved from http://www.wmich.edu/evalctr/checklists/kec_feb07.pdf Vitasek, K., Harrity, C., O'Donoghue, K., & Symmes, S. (2007). Warehousing & fulfillment process benchmark & best practices guide. Retrieved from http://www.werc.org/assets/1/workflow_staging/Publications/701.PDF 24
  • 26. Appendix A: MU UPS Receiving Process Assessment Rubrics with Criteria Highlighting Dimension of Sub- Poor Practices Standard Practices Best Practices Merit Dimension Hardware is out of date and limited in Available hardware meets current needs. Available hardware meets current and future INSTRUMENTS quantity or not in an adequate quantity. needs. Hardware Hardware is properly maintained and (Non-Electronic) - Available hardware does not meet current functional. Backup equipment is available to replace out WEIGHTING: includes forklifts, needs. of service equipment. pallets, shelving, Important conveyors, bins Hardware is out of repair or requires Hardware is efficient and does not add excessive service. additional steps to work processes. Hardware is not mobile. Hardware is mobile. Hardware is highly mobile and compatible with the latest software. Hardware is out of date and not Hardware is compatible with newer compatible with newer software. software. Available hardware meets current and future needs. Hardware is out of date and limited in Available hardware meets current needs. Hardware quantity or not in an adequate quantity. Backup equipment is available to replace out (Computerized) Hardware is properly maintained and of service equipment. Available hardware does not meet current functional. needs. Hardware is efficient and does not add additional steps to work processes. Hardware is out of repair or requires excessive service. Software is slow, not easy to understand, Software can be learned within an Software is easily understandable and easy to and not efficient. acceptable time period. use. Software does not interface with the next Software interfaces with - and can be Software is easily upgradeable and easily area in the receiving process. retrieved by other parts of the receiving integrates with other company software. Software process. Software provides metrics that can be Software can be upgraded when provided to customers. requirements change. Software is updated regularly to support best practices. 25
  • 27. Dimension of Sub- Poor Practices Standard Practices Best Practices Merit Dimension Pallet placement is not formalized Pallets are laid out so that they do not hinder Product placement is clearly defined. WORKSPACE movement. Package placement is not clearly defined Sorting area is arranged to support demand Package placement is clearly defined. issues meeting current and future volume. WEIGHTING: Sorting area is not arranged to support Pallet Layout Very Important demand Issues meeting current volume. Pallets are laid out to optimize movement, and restrict fatigue or injury. Mobility around pallet area is difficult. Floor space is poorly laid out and mobility Fixtures are placed so that they do not Floor space is well laid out to support current is difficult. hinder movement of product. and future demand. Utilization of Floor Space Poor layout in high traffic areas. Poor Areas are laid out well to support current Area is kept clean and clear of debris. housekeeping demand. Floor space does not meet current needs. Floor and storage space meets current Floor and storage space is adequate to needs. accommodate current and future demand. There is not enough room to unload an entire truck during peak times. There is adequate space to unload a truck Space Available and still allow for mobility. Storage space is not adequate to hold overstock during peak times. Storage space is adequate to hold overstock during peak times. 26
  • 28. Dimension of Sub-Dimension Poor Practices Standard Practices Best Practices Merit Trailer deliveries not scheduled Shipper given specified delivery window Doc appointments are made and a Process commitment to unload every vehicle within Dock Management Management Trailers not unloaded in a timely way Timely unloading to avoid two hours when the appointment is kept, detention/demurrage labor and dock space utilization is optimized No package labeling OR package Not all packages labeled by suppliers, but is Package is labeled by supplier, to Weighting: inconsistently or incorrectly labeled labeled upon receipt specification receipt so check-in can be Package Labeling made with bar-code scan into the system Extremely Important Documented Standard No process documentation exists OR Receiving processes are documented and Receiving processes documented, made Operating Procedure processes are written but not consistently available but tacit knowledge is not made readily available, and consistently followed (DSOP) followed or made available explicit Customer shipping errors are not tracked Ad hoc process to track inbound receiving Basic receiving requirements are outlined (e.g. % of packages errors or track internal functional metrics and shared with all customers received without a invoice or % of packages received mislabeled) Customer receiving errors are not shared Formal process to collect inbound receiving with customers metrics and data is shared with customers No established performance Basic receiving requirements are outlined and Internal performance metrics are collected metrics or SLAs shared with all customers and posted or shared with employees (service level Metrics agreements) Formal process to collect Inbound receiving established with metrics, but data is not shared with suppliers customers Internal performance indicators (e.g. dock to stock time) are not tracked 27
  • 29. Appendix B: Summary of Ratings with Rationale Dimension of Sub-Dimension Rating Rationale Merit The criteria for non-electronic hardware all fall under the Standard Practices rating. Hardware (Non-Electronic) Standard Practices According to one stakeholder, some of the existing hardware will require replacement in the near future but all equipment is currently adequate. The criteria for computer hardware all fall under the Standard Practices rating. The Instruments Hardware (Computerized) Standard Practices laptops are not modern, but have sufficient capacity to run the necessary software. The criteria for software all fall under the Standard Practices rating. The software was Software Standard Practices created in-house and continues to meet the organization’s needs. The criteria for pallet layout all fall under the Standard Practices rating. There is no Pallet Layout Standard Practices consistent layout plan for pallets, but the crew members are successfully able to create the layout for daily conditions. The criteria for utilization of floor space all fall under the Standard Practices rating. Space Workspace Utilization of Floor Space Standard Practices is limited, but the crew reports no significant problems in navigating the space under normal volume conditions. The criteria for space available all fall under the Standard Practices rating. The space does Space Available Standard Practices accommodate current normal volume, but is less able to accommodate peak volume. There is no room for future expansion. The criteria for dock management all fall under the Standard Practices rating. The main Dock Management Standard Practices issue with shipment delivery is related to the reliability of UPS delivery employees, which MU cannot control. The criteria for package labeling all fall under the Standard Practices rating. Current Package Labeling Standard Practices package labeling is adequate, but MU is looking at ways to improve it. Process Management The criteria for DSOP fall under the Poor Practices rating. There is no documentation of Documented Standard Operating Poor Practices standard operating procedures. All knowledge is tacit and communicated verbally to new Procedure (DSOP) employees. The criteria for metrics all fall under the Poor Practices rating. No performance metrics Metrics Poor Practices exist, nor do any methods of measuring aspects of performance. 28
  • 30. Appendix C: Data Sources for Instrument Dimension Interviews Sub-Dimension Data Sources Observation Extant Data Truck Crew Supervisors (1) Extant Data – Q11: Can you think of one thing that you use now Q: How long do the Pallet Equipment Inventory Review equipment (like a piece of equipment or a procedure) that Jacks typically last before includes: inventory. prevents you from working faster or more they need to be replaced? Review maintenance accurately? Forklift (n=2) records a. No -TC #1 With the amount of use they Pallet Jack (n=4) get during our receiving Express Belt Hardware (non- (2) Interviews – b. Not really offhand. Space is the biggest hindrance. process, they typically have a w/computer (n=4) Management (n=3) TC #2 lifecycle of 3 – 4 years. Two Roller (n=1) electronic) and Crew (n=4). of the Pallet Jacks have been Pallets c. Some of the belts aren’t that good for rolling boxes. in use for 3 years, and two Bins (n=2) When these belts are extended, the rollers are too far have been in use for 6 – 7 apart and don’t roll boxes easily. TC #3 years. Truck Crew d. Nothing that gets in my way. The other guys get in Supervisor my way because of the limited space. TC #4 (1) Extant Data – Q13: How would you improve the layout of your Computerized Review equipment work area? Inventory includes: inventory. d. The racks are not very sturdy. TC #4 Review available Computer with Hardware hardware scanner (n=3) specifications. (Computerized) (2) Interviews – Management (n=3) and Crew (n=4). (1) Interviews - Q7: How long does it take you to do the data entry Q1: How long have you Management (n=3), for each package? How easy is it to use the software been using the current Crew (n=4), to do the data entry? How easy is it to make software? Programmers (n=1). corrections if you type something wrong? The software has been Software a. 15 sec - 1.5 min (depending on how many unchanged for the last 15 packages) Labels without bar codes = does not add years. significant extra time to initiation To edit data entry, search by invoice # and edit, very simple. Receiving cannot access this software - if they find an error, they bring it to the truck crew’s attention so the truck crew 29
  • 31. can make the correction. Can track which truck crew member made the error, but not known if accuracy problems are tracked and taken into account for performance reviews -TC #1 b. 3-4 minutes at the longest. Very repetitive once you learn the process should be quick (his time is longer because he is new). Easy up to a point until you get to the 2nd to last screen. Once it gets to that point it would have to be corrected by supervisor -TC #2 c. Not long, I just scan the barcode and UPS code (these packages have standard UPS labels, I assume). I have to open the packages occasionally to get a packing list, but in most cases I just scan it. It’s easy to make corrections. TC #3 d. Maybe 10 seconds, 20 seconds - I’ve been here 10 years so I can fly through it. The software is really easy to use, and I can barely send an e-mail! Software is not complex. Everybody has their own log-in, but not everybody has editing permission. Supervisor and unofficial assistant supervisor can make changes if errors are found at the end of entry TC #4 30
  • 32. Appendix D: Data Sources for Workspace Dimension Interviews Sub-Dimension Data Sources Observation Extant Data Truck Crew Supervisors (1) Interviews - Q6: How easy is it to sort the large packages so that Pallets are laid out in Management (n=3) all the packages from one sender are together? Are rows but package layout and Crew (n=4). the labels consistent or do you run into problems is not standardized. with labels having different names for one sender? (2) Observation - Observe receiving b. It’s fairly simple, my biggest problem was spending process to determine too much time trying to remember where I had put product placement things down, this became easier with practice. trends. Sometimes pallets are organized by #, other times by return/guide/etc - it depends on who sets up the pallets. TC#2 Q13: How would you improve the layout of your work area? a. The racks used to run the opposite way, but that reduced the loading area so we changed the rack Pallet Layout orientation to give us more space. Racks are almost to the ceiling now, at max height for forklifts -TC#1 b. A branching conveyor belt - pull off different categories-guides, returns, and others This would probably take up a lot of space, but would make it easier to sort and pallet. TC #2 c. More space. Not sure offhand what would help the layout. (moving student returns to another part of the building - would require a different address and would only eliminate one roller) TC#3 d. Just expand, honestly. TC #4 31
  • 33. (1) Interviews - Q12: Is there anything about the physical layout of There is a choke point Management (n=3) your warehouse area that gets in the way during between the third and Crew (n=4). normal weeks? What about during high-volume Express Belt and the weeks? Roller. (2) Observation - a. High volumes SKUs that have no invoice (labeling), Observe receiving having to wade through many packets -TC#1 Every open space is process to determine used, with narrow paths Utilization of product placement b. The track area coming from the belt to the student to walk though. trends and floor space returns is a high-traffic area and is pretty tight for Floor Space usage. space. (area around the first computer - the rack is close to the conveyor, causes a bottleneck). Takes more time because you have to detour with the forklift. TC #2 c. In a normal week no, but yes during a busy week. TC #3 (1) Interviews - Q6: How easy is it to sort the large packages so that Every space is used. Management (n=3) all the packages from one sender are together? Are and Crew (n=4). the labels consistent or do you run into problems with labels having different names for one sender? (2) Observation - a. The larger the load the harder it is. Space makes it Observe receiving area hard (after you get so much you forget where you put to determine space it). Senders sometimes put the wrong information availability. (like name of individual rather than name of school) or no information (they don’t understand they are NOT the only vendor) -TC#1 Q8: During normal times, is it easy to move the Space Available packages around to where they need to go? a. Pretty easy but space is limiting -TC#1 b. Yes - TC#2 c. Pretty Easy TC # 3 d. Normal times yes but space is also an issue during busy times. Freight (pallets) is bumping into other shipments. Q9: How does your work routine change during those weeks when the number of inbound packages is twice the usual volume? a. It’s a lot more fast pace. Where we’re rushed we are out of space quickly and it can be backed up for 5- 32
  • 34. 6 weeks. When outbound is busy, inbound personnel are diverted there to help, which slows down the inbound processes. -TC#1 b. Between freight coming off and coming in, space becomes very tight, hard to move around with the forklift because there’s stuff everywhere.-TC #2 c. Space (paraphrase) TC #3 Q10: Can you think of one thing that could be added to your work area that would make your job easier? a. Space -TC#1 b. More space, definitely more space TC#2 c. When I scan, wondering why it can’t be done about the people that are checking it in. Seems like initiation is redundant - why not just put student returns in the bins and have the direct receiving group do the check-in? Jerry and the rest of the crew are in favor of this. This would both remove duplication of effort and free up space that the student return rollers currently take up. TC#3 33
  • 35. Appendix E: Data Sources for Process Management Dimension Sub-dimension Data Sources Observation Extant Data Truck Crew Supervisors (1) Interviews - Q4: How much time is there between the time you The UPS Truck is Management (n=3) start work and the time the first UPS truck arrives? available before the and Crew (n=4). a. Anywhere from an hour to 1.5 hours, depending on truck crew arrives. if we have the usual UPS driver. We come in at 7, the However, it cannot be (2) Observation - drivers don’t come in until 8:30 -TC#1 unloaded until the Observe unloading driver is ready. process and record b. When they have the normal driver, he’s usually times to completion. here about 8:30-9. When he was changing his job, the communication over at UPS was off - the driver would show up late, we would have to call UPS to find out Dock where the truck was. -TC #2 Management c. Depends on driver (8:15-10am).. Sometimes there is packages left in receiving from the day before that they can unpack until the driver is there TC#3 The truck trailer gets there before we do (it’s driven over and left - the truck cab goes off on another job). d. The truck trailer gets there before we do (it’s driven over and left - the truck cab goes off on another job). TC#4. (1) Observation Q6: How easy is it to sort the large packages so that Weaknesses in receiving Labels are colored, No package labeling all the packages from one sender are together? Are process depending on the type documentation exists. (2) Interviews - the labels consistent or do you run into problems There are 7 to 9 different of delivery. Management (n=3), with labels having different names for one sender? variations for any given ISBN No documentation exists Crew (n=4), and a. Senders sometimes put the wrong information (book sorted by type of Customers do not to inform customers of Package Programmers (n=2). (like name of individual rather than name of school) edition and physical always properly label how to properly label a or no information (they don’t understand they are condition). Returns may not packages. package. Labeling NOT the only vendor) -TC#1 be classified correctly by the store/buyback, or returns Sometimes customers c. The count can sometimes be off but as long as the received may not have forget to put labels on labels are there. On the majority, the labels are there originated at MBS in the packages. -TC #3 first place. Returns come in from stores, buyback When customers ship 34
  • 36. d. It’s pretty simple after doing it for so long. Store contractors, and individuals multiple packages, UPS numbers are written on the packages, so we get used - labeling not consistent, does not always deliver to looking for store numbers to match up shipments. may not be accurate. them in the same Labels are mostly consistent, but I have seen Guaranteed buybacks pre- shipment. packages with label but no information or that have labeled for accuracy. just the sender’s first name and not the last, or boxes Department would like to Barcodes on the with no labels (it’s a sticky tag that may accidentally look into more bar code package label only get peeled off during shipment) -TC #4 information. Right now the include the UPS receiving crew has to input Shipping number. much information manually. Inconsistency in how No customer education bookstores label returns, so process exists at any receiving crew won’t have level of the company accurate information (so to inform shippers of billing for returns may be proper procedures. inaccurate because returns from a given store may not be processed as a group).- Operations Manager Problem with Invoicing of shipments, improper labeling, and improper counts - weaknesses are on the sender side. If sender information is correct, receiving goes like clockwork. Biggest problem is that improper identification. Truck Crew Supervisor (1) Extant Data - Q3: When you first started, was there any part of New hires should be None Available Review receiving and the unloading and check-in process that took a little comfortable within a 2-3 Document shipping process more time to learn? How long did it take for you to week time frame, by then documentation. feel pretty comfortable doing your job? we’ll know if they can cut it. Standard a. Took about a week to get comfortable with the They receive OJT. Just the Operating (2) Interviews - entire process (including the computer). TC #1 hands-on responsibility. Go Management (n=3) b. It was all kind of new to me, so I learned one thing through proper lifting Procedure and Crew (n=4). at a time - there’s a lot to learn at once, so I had to methods (safety training, I (DSOP) break it down. Had to learn the difference between assume) . This (receiving what’s a return and what’s a guide. I’m used to having process) is a new beast even written directions/ guidelines, but all instruction here if you have dock experience. 35
  • 37. was verbal and each person had his own way of doing Can be overwhelming even things. It would have helped if I had something to with experience. The read that was standardized. Without that, I wasn’t sorting is the hardest part of able to learn something until I actually needed to do the learning curve. (labeling, it. I didn’t think any particular process was more categorizing). The guys difficult to learn than another. I started at the already do categorization on beginning of a buyback rush so I was thrown into it - floor. Ebb and flow of learned the motions, wasn’t able to get more in- volume would not really depth until rush was over. -TC# 2 make a color coded floor c. Took about a week to get comfortable with the labeling system feasible -- entire process (including the computer). TC#3 Truck Crew Supervisor d. The unloading part. I’m not really computer savvy, but it’s easy to pick up. With unloading, had to learn the different shipment types. Took about two weeks tops to feel comfortable. TC #4 Q14: If you were in charge, how would you improve the efficiency of the receiving process? a. I don’t know if there’s really any way to improve (the people). Nothing I can think of offhand. TC #1 b. When bringing someone in - I can pick up things quickly because of my training but it might be hard for others. I see it as a weeding out process to see who they want to keep, but it would help to have a truck crew-specific training manual and job aid. Documented SOP - there’s isn’t one now. For example, a standardized way of setting up the pallets. TC #2 c. Current method is good as long as team works together. TC#3 d. The number one thing is space, then the timing for UPS arrival - we get here at 7 but he doesn’t get here until later. TC #4 (1) Extant Data - Setting benchmarks for None Available Review receiving and future evaluations; shipping metric establishing regular re- documentation. assessments of receiving Metrics processes; defining ideal (2) Interviews - performance for individuals; Management (n=3) defining ideal performance and Crew (n=4). for the receiving team; exporting elements of the 36
  • 38. receiving processes to other parts of the organization; and/or developing evaluation processes for other parts of the organization. -Operations Manager Would like to see more metrics [in receiving process} such as copies checked per hour, book shelved per hour no formal written documentation - Inbound Manager 37
  • 39. Appendix F: Sub-dimension Weighting of Importance by Stakeholders Sub-Dimensions Inbound Manager Operations Manager Truck Crew Manager Hardware Extremely Important Important Extremely Important (non-electronic) Hardware (Computerized) Extremely Important Important Extremely Important Software Very Important Very Important Very Important Pallet Layout Important Important Extremely Important Utilization of Extremely Important Extremely Important Extremely Important Floor Space Space Available Extremely Important Very Important Extremely Important Dock Management Extremely Important Important Extremely Important Package Labeling Extremely Important Very Important Extremely Important Documented Standard Operating Important Important Important Procedure (DSOP) Metrics Extremely Important Very Important Important 38
  • 40. Appendix G: Scoring Rubrics for MU UPS Receiving Process Evaluation Rubric for Ranking Importance Rubric for Ranking Sub-Dimensions Standard Important Very Important Extremely Important Poor Practices Best Practices Practices 1 2 3 1 2 3 Sum of Weighted Dimensions Weighting Value Sub-Dimension Dimension Weighting Sub-Dimension SDR Value (R) IxR (I) Rating (SDR) 1 Hardware (non- Standard Practices 2 2 electronic) INSTRUMENTS Important Hardware (Computerized) Standard Practices 2 2 1 1 Software Standard Practices 2 2 Sum of Importance and Rating 6 2 Pallet Layout Standard Practices 2 4 Utilization of WORKSPACE Very Important 2 Floor Space Standard Practices 2 4 2 Space Available Standard Practices 2 4 Sum of Importance and Rating 12 3 Dock Management Standard Practices 2 6 3 Package Labeling Standard Practices 2 6 Extremely PROCESS MANAGEMENT Important Documented Standard 3 Operating Procedure (DSOP) Poor Practices 1 3 3 Metrics Poor Practices 1 3 39 Sum of Importance and Rating 18 Total Sum of Weighted Dimensions 36
  • 41. Score Combinations for Dimension Rating Dimension Lower (L) Sub-Dimension Weighting Poor (P) Mediocre (M) Acceptable (A) Very Good (V) Excellent (E) Boundary (W) Most sub-dimensions Most sub-dimensions Most sub-dimensions Most sub-dimensions receive a 1, and one receive a 2, and one receive a 2, and one receive a 3, and one All sub-dimensions All sub-dimensions sub-dimension sub-dimension sub-dimension sub-dimension received a 1 receive a 3 receives a 2 for each receives a 1 for each receives a 3 for each receives a 2 for each Dimension Dimension Dimension Dimension Hardware (non- 1 1 1 1 2 2 3 electronic) Hardware 1 1 1 2 2 3 3 (Computerized) Software 1 1 2 2 3 3 3 Pallet Layout 2 2 1 1 2 2 3 Utilization of Floor 2 2 1 2 2 3 3 Space Space Available 2 2 2 2 3 3 3 Dock Management 3 3 1 1 2 2 3 Package Labeling 3 3 1 2 2 3 3 DSOP 3 3 1 2 2 3 3 Metrics 3 3 2 2 3 3 3 40