Dorman Case Study | Zebra

Summary

The video script discusses Dorman Products, an aftermarket automotive company, and their journey with continuous improvement, particularly focusing on reducing travel waste. The team, consisting of four members, has implemented Automated Material Retrieval Systems (AMRS) to streamline operations, resulting in a 16% increase in picking productivity. The AMRS, including the Cart Connect 100 and 1500 series, have revolutionized the picking process, especially for e-commerce orders. The script also hints at future applications, such as housekeeping automation, and advises other companies to identify and address waste in their processes. Zebra's plug-and-play application is praised for its ease of use and scalability.

Takeaways

• 🚗 Dorman is an aftermarket automotive company specializing in car repair parts.
• 🔑 The speaker leads a continuous improvement team with four members, each with a specific focus area.
• 🌐 The team identifies travel as the primary waste, with over 15,000 miles traveled monthly.
• 🚚 Efficiency is improved through reducing travel and utilizing automation to streamline processes.
• 🛠️ The company uses Cart Connect 100 series and 1500 series for different workflow needs.
• 📦 The 1500 series is for full pallet moves, while the 100 series is for outbound picking, especially for e-commerce.
• 📈 AMRs (Autonomous Mobile Robots) have increased picking productivity by 16% and improved picking rates.
• 📦🚪 There has been a decrease in product on the dock due to the efficiency of the AMRs.
• 🗑️ Future use cases for AMRs include housekeeping, such as managing waste from 70 trash cans across the facility.
• 💡 The speaker advises other companies to start small with automation, focusing on improving the end of their processes.
• 🔧 Zebra's Plug and Play application is highlighted as a good choice for companies with a strong understanding of their internal processes.

Q & A

What is Dorman Products' primary business focus?

Dorman Products is an aftermarket automotive company that specializes in providing replacement parts for repairing cars.

What is the main role of the continuous improvement team at Dorman Products?

The continuous improvement team at Dorman Products is responsible for identifying and reducing waste, particularly focusing on travel and product movement within the facility.

How many team members are there in the continuous improvement team, and what are their specific focuses?

There are four team members, with one focused on inbound processes, one on outbound, and one specific to automation, while the fourth's focus is not mentioned in the transcript.

What is the primary waste identified by the team in Dorman Products' operations?

The primary waste identified by the team is travel, which amounts to over 15,000 miles in a given month.

What are the two primary workflows being used in Dorman Products' operations?

The two primary workflows are the Cart Connect 100 series for inbound processes and the 1500 series for full pallet moves and outbound picking.

How does the 1500 series workflow function in Dorman Products' operations?

The 1500 series workflow is used for full pallet moves, where pickers pick items to a palette, and once full or the order is complete, it is dropped off to be loaded onto a P&D stand for the 1500 series to bring to the dock.

What role do the Cart Connects play in Dorman Products' outbound picking process?

The Cart Connects are used for the outbound picking process, particularly for e-commerce orders, allowing pickers to offload material directly to the Cart Connect for expedited processing to the rush area.

What is the reported improvement in picking productivity due to the use of AMRs (Automated Mobile Robots)?

The use of AMRs has improved picking productivity by 16%, which is directly correlated with an improved picking rate.

How has the implementation of AMRs impacted the product on the dock at Dorman Products?

The implementation of AMRs has resulted in a decrease in product on the dock, as the robots follow a set map and navigation points efficiently.

What future use case for AMRs is Dorman Products considering to tackle waste in their processes?

Dorman Products is considering using AMRs for housekeeping tasks, such as emptying trash cans throughout the facility, to reduce the travel and waste associated with this process.

What advice does the speaker give to other companies looking to automate their processes?

The speaker advises other companies to look at the wastes within their existing processes and start small, learning how to scale the model up, emphasizing that the sky is the limit on what can be done with automation, limited only by one's imagination.

Why is Zebra considered a good choice for companies with a strong understanding of their internal processes?

Zebra is considered a good choice because it offers a true Plug and Play application, allowing the bots to be quickly uncrate, loaded into the map, and ready to go, making it easy for companies to implement and utilize.

Outlines

00:00

🚗 Dorman's Automotive Parts and Continuous Improvement

The script introduces Dorman Products, an aftermarket automotive company, and discusses the role of the Continuous Improvement team led by the speaker. The team, consisting of four members with specific focuses, identifies travel as the primary waste in their operations, with employees traveling over 15,000 miles per month. The speaker emphasizes the importance of efficiency and the potential of automation to reduce this waste, particularly in the context of material handling and e-commerce fulfillment.

📦 Workflow Optimization with Cart Connect Systems

This paragraph delves into the specific workflows used by Dorman Products, highlighting the Cart Connect 100 and 1500 series. The 1500 series is used for full pallet moves, where pickers fill pallets and then transport them to a loading area. In contrast, the Cart Connect system is employed for outbound picking, especially for e-commerce orders, which are typically smaller and require faster processing. The system allows pickers to offload materials directly to the Cart Connect for quicker delivery to the rush processing area.

📈 Increased Productivity through Automated Material Robots (AMRs)

The speaker discusses the impact of Automated Material Robots (AMRs) on picking productivity, noting a 16% improvement. This increase in picking rate has led to a decrease in product time on the dock, as the AMRs follow set maps and navigation points efficiently. The script suggests that the AMRs' adherence to a structured process contributes to the overall efficiency gains.

🔮 Future Use Cases for AMRs and Advice for Automation

The script outlines potential future applications for AMRs, such as housekeeping tasks, to further reduce waste associated with travel within the facility. The speaker advises other companies looking to automate to first identify and address waste in their existing processes. They recommend starting small and scaling up, emphasizing the ease of implementation with Zebra's plug-and-play application. The speaker concludes by suggesting that the only limit to what can be achieved with these bots is one's imagination.

Keywords

💡Continuous Improvement

Continuous Improvement refers to ongoing efforts to enhance processes, products, or services. In the video, the speaker leads a continuous improvement team focused on optimizing operations, reducing waste, and boosting efficiency in areas like inbound, outbound, and automation. This concept is central to the company’s goal of refining their logistics and operational workflows.

💡Travel Waste

Travel Waste refers to the unnecessary movement of workers or products within a facility, leading to inefficiency. The video highlights how travel is the primary source of waste identified by the speaker’s team, with employees traveling over 15,000 miles monthly. Automating some processes helps to reduce this waste and improve overall efficiency.

💡AMRs (Autonomous Mobile Robots)

AMRs, or Autonomous Mobile Robots, are robotic systems that navigate and transport goods within a warehouse or facility autonomously. The video discusses how these robots are used to tackle travel waste and streamline product movement, contributing to a 16% increase in picking productivity. Specific models like the Cart Connect 100 and 1500 series are mentioned as crucial in the company’s automation strategy.

💡Cart Connect 100 Series

The Cart Connect 100 Series refers to a specific type of AMR used primarily for e-commerce picking processes. In the video, these robots handle smaller, time-sensitive orders by transporting them directly to a rush processing area, ensuring quicker order fulfillment. The role of these robots is highlighted in improving e-commerce operations by reducing manual effort and travel time.

💡Cart Connect 1500 Series

The Cart Connect 1500 Series is another type of AMR designed for moving full pallets. The video describes how these robots take over tasks like transporting completed pallets from pickers to the docking area. By automating this process, the company reduces manual labor and ensures efficient, consistent product movement across the warehouse.

💡E-commerce

E-commerce in this context refers to the handling and processing of online orders that are smaller in volume but require quick delivery. The video emphasizes how the company’s e-commerce operations benefit from automation, particularly through the Cart Connect 100 Series, which ensures fast processing of urgent orders. Automation is key to meeting the high demand and speed expected in e-commerce.

💡Picking Productivity

Picking Productivity refers to the efficiency with which items are selected and prepared for shipment in a warehouse. The video mentions a 16% improvement in picking productivity, directly linked to the use of AMRs. This increase in efficiency not only speeds up order fulfillment but also reduces the strain on human workers.

💡Housekeeping

Housekeeping in the context of the video refers to the management and upkeep of the facility, such as waste disposal. The company is exploring the use of AMRs to handle tasks like emptying trash cans spread across the warehouse. Automating such repetitive and time-consuming tasks further reduces travel waste and labor costs.

💡Waste Reduction

Waste Reduction involves identifying and eliminating non-value-adding activities within a process. The video discusses how automation, such as deploying AMRs, helps reduce waste by minimizing unnecessary travel and optimizing workflows. The continuous improvement team focuses heavily on identifying waste in existing processes and addressing it through targeted solutions.

💡Plug and Play

Plug and Play refers to technology that is simple to set up and use, requiring minimal configuration. The video highlights how the AMRs offered by Zebra are easy to integrate into existing systems. Once they are uncrated and mapped, they are ready to perform tasks, allowing companies to quickly scale automation without complex setup processes.

Highlights

Dorman is an aftermarket automotives company specializing in car repair parts.

The speaker leads a continuous improvement team with four members, focusing on various aspects of the operation.

Travel is identified as the number one waste, accumulating over 15,000 miles monthly.

The team is exploring automation to reduce labor and improve efficiency.

The Cart Connect 100 series and 1500 series are primary workflows for material handling.

The 1500 series workflow is used for full pallet moves to the dock.

Cart Connect is utilized for outbound picking, especially for e-commerce orders.

AMRs have improved picking productivity by 16%, with a direct correlation to an improved picking rate.

There's a decrease in product on the dock due to efficient navigation by AMRs.

Future use cases for AMRs include housekeeping tasks, such as managing trash cans.

The speaker recommends starting small with automation and scaling up after learning.

Zebra is highlighted as a good choice for companies with a strong understanding of their internal processes.

Zebra's Plug and Play application allows for quick setup and deployment of bots.

The potential of bots is limited only by one's imagination, emphasizing the importance of creative thinking.

The speaker emphasizes the importance of understanding and improving existing processes before automating.

The transcript showcases the practical applications of automation in an automotive parts company.

The speaker shares insights on how to tackle travel waste and product movement within a facility.

The efficiency gains from automation are quantified, with a 16% improvement in picking productivity.

Transcripts

foreign

[Music]

products is an aftermarket automotives

company if you ever need to repair your

car there's a good chance Dorman has the

part to do that

I lead a continuous Improvement team I

have a team of four one focused on

inbound one on outbound and one specific

to automation

the number one waste that my team always

identifies is travel if you add up the

amount of travel that they do any given

month it's over 15

000 miles

efficient outside of just bringing in

additional head count labor and

automation just makes sense overall

specifically amrs in regards to how can

we start to tackle some of that travel

waste and just product movement through

the building

the primary workflows that are being

used throughout the operation we have

the cart connect 100 series and the 1500

series

our 1500 series workflow is for full

pilot moves so most of the time the

pickers will pick to a palette when the

pallet's full or that order is complete

they'll drop it off that'll get loaded

to a pnd stand for the 1500 series to

bring to the dock

we utilize the cart connects for our

outbound picking process so we do a lot

of e-commerce here as well and

e-commerce are much smaller orders I

need my part today

and so to expedite that e-commerce

process our Pickers have the ability to

offload that material to the car connect

to be ran directly to our Rush

processing area to get it out the door

as quickly as possible

the amrs have improved picking

productivity specifically by 16 and

we're seeing that directly correlated

with an improved picking rate we've

actually seen a decrease in

product on the dock if I tell it to go

to stage 17 it's going to Stage 17. it's

following a set map it's following a set

navigation point and it's going there

some use cases in the future for AMR is

that we're looking at right now one is

housekeeping actually so we have

something like 70 trash cans throughout

our entire facility that we pay someone

on each shift to go trash can to trash

can dumping one into the other again a

lot of travel and a lot of waste

Associated that process

if you're another company looking to

automate I recommend looking at the

wastes within your existing process we

said if we can improve that very end of

the process we'll make a massive

Improvement start small and learn how to

scale that model up

zebra is such a good choice for any

company that has a really good working

knowledge of their own internal

processes for the fact that it is a true

Plug and Play application we uncrate

these Bots we load them into the map and

they are ready to go the sky is the

limit on what you can make these Bots do

your imagination is the barrier you got

to break through