A3 Problem Solving (Warehouse Pick Errors)

flowchart LR
  subgraph Plan
    A1[Background: 1 line in 240 mispicked, 3 customer claims a week]
    A2[Current state: paper pick lists, look-alike SKUs sharing a bin face]
    A3[Target: 1 in 1000 by week 12, claims below 1 a week]
    A4[Root cause: no scan verification and no visual separation at the pick face]
  end
  subgraph Do
    B1[Countermeasure 1: one SKU per bin face]
    B2[Countermeasure 2: scan-to-confirm at pick]
    B3[Countermeasure 3: colour band on look-alike labels]
  end
  subgraph Check
    C1[Mispick rate plotted daily on the zone board]
    C2[Pick rate watched for a productivity penalty]
  end
  subgraph Act
    D1[Standardise across the other three zones]
    D2[Fold scan-to-confirm into the induction training]
  end
  A1 --> A2 --> A3 --> A4 --> B1
  B1 --> B2 --> B3 --> C1
  C1 --> C2 --> D1 --> D2