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.