Project Status Update P10714 -Cooper Vision

Aditya ManjrekarIndustrial and Systems Engineering

KGCOE, RIT.

Project Status UpdateProject Name Cooper Vision

Project Number P10714

Project Family Lean Production

Track Process Innovation

Start Term 2009-1 (Fall ) for MSD1

End Term 2009-2 ( Winter) for MSD2

Faculty Guide John Kaemmerlen (ISE)

Industrial Teaching Adviser Phil Bryan

Faculty Consultant Andres Carrano (ISE)

Primary Customer Sarah Pittman, Process Improvement Manager , Cooper Vision.

About Cooper VisionManufacturing prescription contact lenses for five decades Thousands of leading brand names

Hydra soft Vertex Preference Frequency Avaira

America's second largest maker of prescription contact lenses.  #1 maker of toric contact lenses for the correction of astigmatism.

Background InformationThe Cooper Companies, Inc. is a specialty health

care company. Its two business units serve niche markets in the medical device market .Cooper Vision (CVI) markets a broad range of contact

lenses throughout the world. Cooper Surgical (CSI) markets diagnostic products,

surgical instruments, and accessories for the women's healthcare market.

Headquarters at Fairport, NY . Extensive network of facilities in 12 countries across

five continents One of the highest level of on-time order fulfillment

in the industry.

Distribution Center in RochesterCurrently they operate a 250,000 square foot

distribution center in Henrietta, NY. Very good picking system

Pick to light Pick to voice.Automated- Integrated conveyer line.

Normal Order Picking- 24 Hrs goal.Bulk Order Picking- 48 Hrs goal.On hand inventory for any if given product is never

zero.Sarah Pittman, Process Improvement Manager for

Cooper Vision – Alumni of the ISE Department , RIT.

Phase 0: PlanningMission Statement

Product Description /Project OverviewThe facility at Henrietta , is going through process improvement changes to better order fulfillment time , customer satisfaction and streamline their distribution. Value added changes need to made to the system through computer tools ,improvements in facility and equipments and through kaizen events.

Key Business Goals/Project Deliverables The primary business goals of this project are to Improve Order picking and shipping times.Improve Workforce utilization due to variable demand levels.Increase the market share of Cooper vision lenses, by improving customer satisfaction levels.

Primary Market /Project OpportunitiesThe primary market for this is the central distribution facility in Henrietta NY.

Secondary Market /Project OpportunitiesSecondary markets for this system are the other distribution center around USA and the rest of the world , that can use similar tools and improvements to better streamline their distribution and fulfill customer needs.

Stakeholders Cooper Companies- Cooper Vision (CVI) Other Stakeholders in the project include the following:

The Final lens user.The retailer /seller, such as pharmacists and 1800-Contacts.Doctors ,Practitioners.The Community in which the facility resides.

Phase 1: Concept DevelopmentIdentify Customer Needs - InterviewsPrimary Customer(s)

Sarah Pittman and Jim Della Valle of Cooper Vision facility in Henrietta.Not Interviewed yet. Sarah Pittman and Jim Della Valle to be interviewed at the distribution facility during week 6 or 7 in Spring 09.Indicated to the current project team that there are many more improvement tasks that can become future MSD projects.Findings to be captured in the format of a textual document with supporting pictures, charts and tables.

Other Stakeholder(s)Secondary Stakeholder is the RIT Senior Design Program

Interviewed Prof John Kaemmerlen (ISE) in Week 5 , spring quarter.Findings noted in Log Book. Initial knowledge to be entered on Edge .

Past Senior Design Team(s) Interviewed Current Multidisciplinary Senior Design team – Winter/Spring 08-09

with Team Lead Aaron Heyman (ISE) Current usefulResources to draw upon

Documentation of previous Interviews and Brainstorming sessions. Capacity Analysis tool ( Excel based for the Henrietta facility ) white paper that describes in detail the steps taken by the team to complete process

Improvement tasks. Charts and tables describing their findings. Simulation Model created for Advanced simulation course in ARENA.

Phase 1: Concept DevelopmentIdentify Customer Needs - Interpret

Needs Statements: The customer would like to Invest time and money in the MSD

project to get a quality tools and tangible process improvement ideas.

The results of this project should generate computer tool which would be.• accurately represent the real needs of the distribution center.• require minimum training and is user friendly.• alert the user when a given demand input is not realizable given actual capacity of

facility.• visualize all the information on a single screen.

The customer would also like the team to suggest validated process improvement ideas to improve order picking and workforce utilization.

The facility at Henrietta , is going through process improvement changes to better order fulfillment time , customer satisfaction and streamline their distribution.

List of suggested 30 to 50 different improvement tasks. Some primary needs are worked on by current MSD team and

next few tasks need to be completed by future teams.

Affinity Diagram.Order picking and shipping •Decrease order picking time.•Decrease order shipping time•Increase order picking accuracy.•Ship orders within target times.

Demand forecasting•Indicate any trend in weekly, monthly , yearly demand.•Indications of seasonal demands of specific products.

Workforce Utilization

•Determine daily requirement •Indicate if enough workforce is available to fulfill requirement.•Have work force utilization close to 100%

Objective Tree We need

this product because …

Orders need to be shipped earlier.

No Mistakes in picking

No reworking

Faster picking

required.

We need better level of customer satisfaction.

Orders shipped earlier than expected.

High quality of products

shipped.

Correct packaging

and labeling.

Labor needs to be utilized efficiently

Maximum workforce utilization.

High worker job

satisfaction.

Low variable costs.

Function Tree This projectNeeds to …

Indicate Daily labor requirements.

Be easy and quick

Show detailed

requirements

Alert if under

staffed.

Forecast trends in the weekly, monthly & yearly demand.

Allow enough time to hire

more workers.

Indicate changes to the manufacturing

facility

Help in making key decisions.

Improve Picking system

Decrease picking time.

Ergonomic consideratio

n.

Eliminate mistakes

and rework

HOQ Main BodyVOC to VOE Indicate Daily labor

requirements.

Forecast trends in the weekly,

monthly & yearly demand.

Improve Picking system

Orders need to be shipped earlier

5 1 9

We need better level of customer satisfaction

3 7 7

Labor needs to be utilized

efficiently9 7 5

Future Plan Discuss and finalize Staffing requirements Discuss and finalize Resource requirements. Schedule Meetings and Interview key stakeholders. Attend Final design review and poster presentation

of the current MSD 2 team. Document Team Values and Norms. Determine preliminary Work Breakdown Structure. Make and present Final Presentation too include.

Planning:- Mission Statement ,Project Relevance, Staffing , Requirements, Intellectual Property Considerations.

Final Customer Needs :-Final Affinity Diagram, Objective tree, Function tree and HOQ.

Issues & Risks mitigation plan Make Marketing Video for future MSD I, MSD II

students.

Preliminary Schedule

Attending Mid-quarter Design review.Planning to attend

Future customer feedback meetings.Final design review Poster presentation

Wk 6

Wk 7

Wk 8

Wk 9

Wk 10

Staffing requirement

Create work breakdown structure.

Start working on Marketing

video.

Start working on final

presentation.

Present all Deliverables.

Thank you

Questions?