Study Shows a Loss of Nearly 3,000 Hours Due to Unproductive Workflows

Posted on January 16, 2014

The world of manufacturing and distribution is a complex one. Every second can impact the bottom line and inefficient protocols and processes will not only slow the facility down but will most likely cut into the business’ profits.

Time is Money

According to a 2012 survey of 250 supply chain, warehouse and Loss of Hours Due to Unproductive Workflowdistribution managers by Intermec, it was found that “over an eight-hour shift, each worker loses an average of 15 minutes of productivity in an inefficient process. For a small- to medium-sized warehouses with 50 workers, this quickly adds up to nearly 3,000 hours a year, and could be a significantly higher number in larger organizations.”

While most of the managers in the study were tasked with finding cost savings, close to 30% of them had not started a review of the workflow process. Moreover, the managers said that customer complaints or compliance issues would be the only reason they would investigate workflow solutions.

While these answers may be a bit jarring to hear, it really isn’t that surprising. With the constant demands of the job duties, it can be daunting and sometimes near impossible to start an entire review process.

Central Valley Manufacturer Finds Workflow Productivity Solution

Sebastian was approached by a manufacturing and distribution client wanting to address the same types of issues listed above.

The company was in the midst of expanding its operations to handle the demand of increased processing pet food for a large chain retailer and needed to ensure that its internal processes would be able to handle the additional data processing.

Specifically, the client wanted to create a secure internal wireless communications system that would allow them to track inventory inside the facility without interference from outside network signals.

Sebastian was able to create a streamlined system that would allow employees to walk the floor of the plant and access any and all information via a tablet. The Ruckus wireless access points along with the Ruckus wireless controller allows the system to be secure by only allowing the wireless signals from the access points to be seen. Signals from cell phones and all other wireless devices are not allowed to be seen by the system.

Making the Investment

Making the time and monetary investment to upgrade the technology used to manage workflow productivity can be extremely daunting. But the numbers don’t lie. Fifteen minutes of lost productivity multiplied by each employee adds up quick. An upfront investment may end up saving you and your company a lot of time and money on the back end.

Image courtesy of Stuart Miles /