Receiving Instructions Inbound Trailer Unloading

Transcription

1 Subject: This work instruction describes how to receive, unload and stage material from arriving trailers and other vehicles, as well as the required handling of critical (Hot Sheet) material. Items in blue font describe automated process using WMS- LINC scanner system and added items. Equipment: 1) Forklift (outdoor usage also) 2) LINC labels & Handheld Scanner General Requirements: 3) Small Parcel Roller Racks 4) Small Parcel Putaway Carts 5) Hot Parts spreadsheet / Manual Pick Orders See Standardized Work Instruction (SW-04: Unloaders; SW-14: Inbound Clerk standardized work instruction). See JSA (Job Safety Analysis). Special Requirements: On average, 40 TL & 14 LTL trailers arrive at the warehouse each day, with 15 to 20 of these trailers being dropped. An additional 8 trailers are received from the Plant with parts everyday (WI-18: Plant OB Shipping Instructions). Refer to WI-13_A: Receiving in WMS standardized work instructions for detailed instructions on how to receive trailers using the LINC WMS. Inbound Trailer Unloading 1) Driver turns in bill of lading and packing slips to Inbound Clerk who verifies trailer is scheduled to correct dock and is within scheduled delivery window time (SW-14: Inbound Clerk standardized work instructions and PM1.1: Inbound) Log actual carrier arrival time next to scheduled window time listed on the Daily Inbound Delivery Schedule sheet Note delivery window discrepancies to the sheet and enter details to the Non-compliant Carrier Report, which is submitted weekly to CNH (PM3.3: KPI Reporting) 2) Supervisor or Inbound Clerk assigns Unloader an inbound trailer to be offloaded. 3) Ensure that trailer is safe to enter by ensuring glad hand lock is applied (SW 02: Safe Trailer Entry & Figure 1)) for all live unloading (trailer is not detached from tractor) and dropped trailers. NOTE: Maximum of 4 hours is allowed to receive and unload live trailers & receipt information into WMS & JDE systems. 4) Enter assigned trailer (Figure 2), unload material & place in designated staging lanes in the Receiving dock area. (Figure 3) If damaged material is found, notify Supervisor immediately & ensure photo of material is taken while it s still on the inbound trailer (refer to PM1.3: OS&D, WI-07: QCR & see next section) 5) Visually inspect each staged part container/pallet for hidden damage or spill. If part container or pallet is obviously damaged or spill exists, note details on the packing slip, tag the container (see photo on page 2) and notify the Supervisor immediately! If damaged material is found, notify Supervisor immediately and ensure photo of material is taken (go to next section). Material staged in Receiving Lanes is ready to be inspected and audited by an Inbound Checker (see next section) 6) Once unloading is completed, ensure to follow trailer release safety procedures (SW-02: pull dock plate, unlock glad hand lock (on dropped trailers) and place door safety chain across dock door entrance) (SW-04: Unloader standardized work) Figure 1: Chocked wheels & trailer lock Figure 2: Entering assigned trailer Figure 3: Staged Material in Receiving Lane Page 1 of 5 Printed: 8/19/2010

2 NOTE: Maximum of 24 hours is allowed to receive and unload dropped trailers & receipt information into WMS & JDE systems. 7) Advise Supervisor / Clerk that trailer is ready for release and perform any additional duties that need to be completed and/or may be requested by the Supervisor Inbound Trailer Verification & Receiving 1) Inbound Checker is assigned Receiving dock staging lane (Figure 3) and is given paperwork for the corresponding unloaded trailer. (SW-09: Inbound Checker standardized work instructions) 2) Checker verifies packing slip (P/S) against part number, package count and purchase order. 3) Checker notates found discrepancies (i.e. overages, shortages or damages or no P/S) onto the Bill of Lading (BOL) or delivery receipt and reports items to the Clerk or Supervisor to initiate corrective action (see PM1.3: OS&D and WI-07: QCR). If no P/S, Clerk will research (in JDE) and enter actual P/S number to receive in WMS. If unable to find P/S number, notify the Material Planner who will call the supplier and fax or P/S to the Clerk. 4) OLI OS&D form is completed, the plant Follow Up dept. is called then correct person is faxed a copy of the form and corresponding BOL. The form is then placed in the designated basket at the Receiving desk (retrieved by the Invoice Resolution Supervisor who will call the appropriate Material Planner & the report on the same day as the shipment was received). NOTE: Damage product is tagged (see example on right) and photos are sent to the logistics onsite to process the OS&D claim against the carrier. For receiving pre-identified QCR material, go to WI-07: QCR Containment & Inspection instructions. 5) Proceed as directed by Follow Up: either receive OS&D shipment as is or move & scan to the designated Receiving dock Audit (Hold) area. The Material Planner is required to instruct within 24 hours of first notification to disposition the load. 6) When receiving non-qcr material that has been flagged for inspection or counting, conduct the audits in the XDock lane that is has been received in: Confirm the Material Planner has edited the identified part s location in WMS with a prefix of Audit (example: Auditprimary location: Audit-RB1MEK1). If no primary location is listed, then enter the word Audit. If the part location reflects just a location, edit the location and enter Audit before the location (i.e. Audit-RB1MEK1) in WMS. Print part label(s) and scan the part label to the Audit floor location bar code label (or manually type the Audit floor location into the scanner and hit Enter to process). Inspect and/or count the identified parts as required and note findings to packing slip. Once the Material Planner confirms the part(s) no longer need to be flagged, confirm the part(s) corresponding WMS location(s) have been updated with Audit being removed in the prefix of the location (i.e. RB1MEK1). 7) Once part verification of lane is completed, return paperwork to Clerk to print LINC labels for each received part (SW-14: Inbound Clerk receiving instructions) Example of QCR tag for possible damage Figure 4: LINC WMS & Scanner Start-Up Example of OLI OS&D form Page 2 of 5 Printed: 8/19/2010

3 8) For direct putaway material, Checker attaches labels to each corresponding part containers/pallets in the staging lane and scans LINC labels to Dock status (Figure 3). NOTE: Material reflecting QCR is moved to QCR corral for containment (WI-07: QCR). 9) For received material needing to be repacked, the label will display REPACK_primary location. Checker applies and scans labels on the corresponding part containers/pallets in the staging lane labels for placement in the Repack Area (WI-12: Repack instructions). 10) Once all labeling is completed, Checker places the reflector stand at the end of the lane to indicate that the staged material is verified and ready to be placed into inventory or moved to the Repack Area (WI-04: Material Putaway; WMS-01: Inbound Scanning). 11) Checker notifies Clerk/Supervisor that the staging lane is completed and receives next assignment. Flatbed Unit Unloading, Verification & Receiving 1) Driver arrives and reports to West Receiving dock (may be redirected to South dock). 2) Flatbed tractor must be turned off and the driver is responsible for un-strapping to prepare the flatbed unit for unloading. 3) Unloader receives paperwork and, using forklift equipment dedicated for outdoor use, goes out into the yard to begin unloading material off the flatbed unit. Note: If the load has multiple Purchase Orders, see a Supervisor for instructions. 4) Unloader must observe if the load arrived untarped: Perform a visual inspection for damage and/or rust to any material and advise Team Lead or Supervisor. (Figures 5 & 6) Ensure photograph is taken on the unit, offload damaged or rusted product and stage for corrective actions. 5) Notate found discrepancies (i.e. overages, shortages or damages) onto the Bill of Lading (BOL) or delivery receipt and report items to Clerk or Supervisor to initiate corrective action (PM1.3: OS&D) 6) OLI OS&D form is completed and placed in the designated basket in the Receiving Office (these are retrieved by the Invoice Processing Supervisor who will call the appropriate Material Planner and the report on the same day as the shipment was received). NOTE: Damage product is tagged & photos are sent to the logistics onsite to process the OS&D claim against the carrier. 7) OS&D shipment is moved to QCR holding area and the Material Planner is required to instruct within 24 hours of first notification to disposition the load (WI-07: QCR). 8) Unloader continues to retrieve material from the flatbed unit, verifies material received against the packing slip/bol details and stages it on the Receiving dock. 9) Once unloading of the unit is completed (Figure 7), Unloader has driver sign the paperwork (and releases the driver), keeps a signed copy and returns to the Receiving office for WMS/JDE systems updating, LINC label printing and paperwork filing. 10) Staged material is audited against WMS/JDE records and printed LINC labels are applied and scanned to Dock status. 11) Received material is ready to be placed into inventory within the warehouse (WI-04: Material Putaway and WMS-01: Inbound Scanning instructions). Example of LINC part label Figure 5: Flatbed of empty racks from Plant to unload Figure 6: Flatbed of material to be received and offloaded in the warehouse Figure 7: Emptied Flatbed Trailer in Yard Page 3 of 5 Printed: 8/19/2010

4 Small Parcel Offloading, Verification & Receiving 1) Dedicated Material Handler is responsible for receiving small parcel packages and putting them away (WI-04: Material Putaway instructions). 2) Obtain packages & any special handling instructions from the carrier driver. 3) Verify consignee information on all packages received: LINC-OLI Warehouse address = 1011 Claude Street, Grand Island, NE Proceed to step 4. CNH Plant address = 3445 W. Stolley Park Road, Grand Island, NE Proceed to step 4. Foreign address = do not accept, return to carrier 4) Verify package count and sign for material if correct. If not correct, verify count with driver, make appropriate notations on carrier paperwork for the overage or shortage, and sign for the adjusted material 5) Record all pertinent information for received packages to the appropriate Log. 6) Take completed Log and all corresponding paperwork into the office for WMS/JDE updating and printing of LINC labels for each part number. 7) Place material onto the roller racks (Figure 8) and separate by warehouse (storage locations and departments) and Plant nonproduction consignments (departments). 8) For warehouse consignments, attach LINC label onto each package and place material onto Putaway Carts (Figure 9). Refer to WI-04: Material Put Away instructions. 9) Move and scan labeled warehouse packages to storage locations and departmental offices (WI-04: Material Put Away and WMS-01: Inbound Scanning instructions). 10) For Plant non-production consignments, place material onto a separate Put Away Cart and move to appropriate dock for the Hot Truck morning shipments to the Plant. Inbound Hot Sheet Instructions CNH Material Planners update the Hot Sheet spreadsheet (which resides on a shared drive Figure 10) to show hot parts (and backreqs ) being expected from suppliers ( /month). 1) Supervisor/Clerk retrieves and prints the spreadsheet, reviews the hot parts ETA to the warehouse, Plant line need times and each receiving area (i.e. small parcel, North and South dock receiving and WMiller). 2) When the hot parts arrive, have the driver turn in bill of lading and packing slips to Inbound Clerk, who verifies hot receipt part is on the trailer and the arrival is within the identified ETA listed to the hot parts spreadsheet (alert Material Planner of discrepancies). 3) Designated Hot Parts person will mark onto the packing slip the quantity and part number that they send hot. 4) Assigned Unloader ensures trailer is safe to enter (SW-02), proceeds to offload & stage material until hot receipt part is found and moves the hot parts to the Hot Truck area (door 23) and places yellow sticker on it. Figure 8: Roller Racks for Small Parcel packages Figure 9: Small Parcel Putaway Carts Figure 10: Example copy of Hot Sheet Page 4 of 5 Printed: 8/19/2010

5 5) If there is no packing slip (P/S): A Hot Sheet Tag (Figure 11) is filled out and placed on the part container that parts were taken from. If all parts were taken from the container, the Hot Sheet Tag is turned into the Receiver. The Hot Part person will Inventory In the part and quantity on the scanner, sending it Hot WMS Manual Order (Release) is entered for the Hot parts When the Receiver gets the P/S, the entire quantity is then received Labels are created for all parts received and the Hot Parts are scanned out of WMS inventory. Example: 75 pieces received and P/S is marked for 25 and 25 pieces sent Hot pieces would be created and the label representing the 25 pieces of Hot Parts is scanned out (Inventory Out) by the person who created the labels. This ensures WMS & JDE records match and the receipt is still correct. Tags that represent the Hot Parts are then thrown into the garbage. 6) If there is a P/S: Parts are received & Manual Pick Order(s) is entered into WMS and the corresponding LINC part label, delivery sheet (with ULOC) & outbound (Pick) labels are printed (WMS- 29: Outbound Pick Order Instructions). NOTE: Parts must be received & available on the line an hour after the truck arrives (if truck did not arrive on time) or at the time indicated in the hot parts spreadsheet. 7) Clerk provides hot part labels and delivery sheet to the dedicated Hot Parts person. 8) The part labels are applied and using the scanner, the hot parts are scanned directly to the Hot Truck location (near door 23). 9) The delivery sheet and outbound label is applied to the container with the yellow sticker. 10) When loading the Hot Truck, the delivery sheet is scanned out, placing the part Order into INT status in both WMS and JDE systems (closing the order in WMS). 11) Hot Truck driver adds orders to his manifest and is released. 12) Upon arrival to the Plant (WI-09), Hot Truck is offloaded and In Plant Putaway-Line Replenisher takes hot part to the ULOC listed on the delivery sheet and outbound label. 13) The delivery sheet is taken off of the container and is submitted to the designated Clerk/Lead/Supervisor. 14) The delivery sheet bar codes are scanned out to take the part order out of INT status and place it into the ULOC. 15) Even though hot part is associated to a Route, no Route Sheets are used when performing line-side delivery on manually-generated hot part Pick Order shipments). SPECIAL INSTRUCTIONS For steel loads that are consigned to the warehouse (and paperwork stamped) yet actually delivered and unloaded at the Plant, refer to WI-42: Plant Steel Receiving instructions. For receiving pre-identified QCR material, go to WI-07: QCR Containment & Inspection. Figure 11: Hot Sheet Tag (in bright Pink) At the end of the shift: 1) Make sure assigned area is clean and free of debris and do not leave any garbage on the forklift equipment 2) Park forklift in designated area and follow equipment return process (refer to WI-31: Forklift Reach Truck Battery Changing and Safety). Page 5 of 5 Printed: 8/19/2010