Archived Most efficient unload/breakout process

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What is your unload/breakout process?
-how are your custom blocks set up along the line?
-how many TMs are on the line?
-how many are bowling?
-do you sort combo repacks on the line during unload or what do you do with them?
-how many bowlers do you have? Are the coming in at 4 or are they staggered?
-what does your wave look like?
-does Br come out and push?
-if your truck is 2200/2300 what time are you finishing everything?

Just want to compare and contrast to figure out the most efficient process. Please feel free to be as detailed as possible
 
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DMNDZ bruhh

Former Backroom Dayside
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Apr 13, 2012
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at my store...
-2-3 unloaders in the trailer
-we have about maybe 7 on the front of the line loading pallets, 3 behind the line for auto back stock
-we have 1 stager
- we have maybe 4 people bowling in various departments like market, chemicals, and babies
-our wave, we start off in market, then we blow our way from chemicals, paper and HBA, then we all head to babies in the end and sporting goods
- in the meen time of all this, there is 1 person in babys, one person in toys, 3 people in C&D, 1 person in stationary, and 2 people in pets and paper and one in electronics
- the backroom team will only push if flow is behind, we used to always knock out toys and then start backstocking everything.
- the LATEST anyone will stay to is til their 5th hour, and usually everything is done by then
 
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A+ Volume store overnight
-7 trucks a week
-avg 1750
-2 unloaders in truck
-1 person scanning
-1 person don dock taking off bulk non conveyable (furn, plas, seasonal, etc.)
-4 bays on front of line
-bay 1 25,26,27 (elec, bed/Dom, seasonal)
-bay 2 28,29,30 (sprt goods, toys, plastics)
-bay 3 31,32,33 (market)
-bay 4 34,35,36 (housewares, Chems, pet/one spot) also 37 (paper)
-that's 4 ppl on front of line
-4 bays on back of line
-3 for bkstk; 1 for soft lines, 1 pallet for push HBA/stat and a flat for repacks(stat/HBA/ pets/ kitchen etc.
2 people on back of line.
-1 person sorts repacks for a/b on the floor with double decker carts during unload.
-3 people breakout soft lines at the horseshoe.
-normally 3 pullers/bowlers + 2 team leads.
We have one wave start in A/B (pets/chem/HBA/housewares/stat/paper.)
We have another wave that does market then e/f
We have one person push dock then join market.
3 or 4 people push soft lines
1 person pulls/pushes/back stocks electronics.
Two to three people push A/b carts(repacks).
Backroom comes out to push if they are ahead or flow is behind.
Back room consists of 4 people a night(32hours)
They come in at 10:30; flow at 11.
We are usually always done by 4:45 before flow has to take a lunch.
Back room goes to lunch at 3:30 and is always finished by 7 am.
We take a food truck 3 nights a week as well. Totes diff way we do things on those nights.
For non food truck nights we avg 17 people for food truck nights 20.
 
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And normally have 1 person push infant hard lines from flow or back room does it so they can get that back stock first.
 
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After A/B wave finishes a/b they move into c/d( beds, Dom, sewing/furn/air filters/fans/ mirrors/lamps/plastics.)
I usually break one person off to push pulls in c/d and one person to sort and push repacks.
 
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Nov 23, 2012
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Every stores custom blocks are different, the ideal is what ever your biggest ones are need to be at the end of the line. At my store.

E/E custom block is first because we always push E/E
Infants and groceries are at the end of the line everything in the middle is based on smallest push to biggest granted not always the same but overall it works.
5 TM push side, 2 backstock side, 2-3 unloaders changing out every 20 minutes or so,1 scanner, 2 pushers - 1 of which is flipping.
generally have 2 pallet pullers and 2 people bowl all grocery, 1 floats between 3 areas D&E and C. We have enough softlines that one of them usually help bowl while 2 others are breaking out.
Softlines break out is also separated 1 for hanging and 1 for folding, keeps them from talking as much.
Repacks, we have 1 person breaking out repacks on the floor during the unload, when truck is done repack team works the repacks while the 1 breakout person stays ahead of them breaking out the next area and they follow.
Wave team starts grocery, then moves to front of HBO to D&E, C, Toys by the time the store opens we have the back of A&B and seasonal.

BR does come out and push when we have the time, I usually have 7-8 backroom TM's scheduled but 1 does the bulk from the truck, 1 is electronics, 1 does my FDC, GRC2, Bev side. But generally BR does handle toys and usually all of C at times.

or trucks generally average 2100 usually Flow is gone by 8:30 or 9am at the latest. BR depending on the day and workload since they are on the floor a lot or usually there till 10 or 11:30 at the latest and those are the big workload days a lot of transition or what have you.
 
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