@FloorReplenishor there is a power point they sent us on exactly how to do it but every store that is still on it is allowed to tweak it up. The reason I say "still" is because there is some stores that couldn't handle it and got off the process. It can be a challenge to execute and can eat up a lot of payroll if not executed right. But if executed right, your store will look amazing everyday. Right now at my store we have certain areas that look amazing everyday and some that aren't, the ones that aren't are usually poor performing TMs, which is being worked on. The process helps them stick out like a sore thumb unlike the wave. But the biggest challenge is not overspending payroll, right now we are overspending because of some productivity issues and some scheduling issues and by this I mean not scheduling some people long enough. Some areas can be done in about 4-5 hours (strays, push, and zone) and some areas take more like 6-7, it's all dependant on wants on the truck.
Now more on your other questions
- On the line we have 1 unloader, 2 on the front, 2 on back, 2 pallet pullers, and usually me or one of the other TLs side by side with the unload team to help push the line. If you are not able to be back there, then it's probably a good idea to have another person to push the line. That can be the difference of about 30-45 minutes cut off your unload time. It on average takes anywhere from 2:30-3:30hrs. At first it will take longer because the team will have to get use to not having so many people on the unload process.
- Once unload is done, they pull all the remaining pallets to the floor, 1 person stays to clean up the remaining stuff in the truck. Once all that is done, they take their break. There shift is usually 4 hrs, so they will stay to help push for a little or just go home early.
- On the floor you have about 26-28 (29-32 total including truck people) We have one person in every area, some nights we have to shift people around to cover other areas or to help in heavier areas.
- Backroom has about 6 people every night. You can have less if your dayside is doing manual CAFs but we stop doing them because it took up a lot of payroll and it was hard to manage.
I love the process because you can have more accountablity with individuals based of their zone, backstock, and timelines and you can recognize the ones that execute they area right, plus the store will look amazing, better then most stores that i have seen, but we are overnight, so it's easier to get things done without distractions. An early AM process would be more of a challenge but still doable.
What I love in my store...the flow team is expected to do the 4x4 every truck day....and they are not given extra hours to offset what they spent doing it ....then they get fussed at for going over on payroll and not getting the truck pushed.
It will be hard to actually have them 4x4 zone, they can but that would mean probably giving every TM a 7-8hr shift, which would be 200+ hrs spent per truck. We get about 170-185 per truck but spend a little more. I would recommend just having a small team specifically for 4x4, like 2-3 people.
If you have any other questions let me know....