You are a supervisor of a material stock area and things are not going well.

Materials that arrive from suppliers are still not put into stock and some rejected shipments are mixed in with those still to put away.

The receiving dock is very congested and disorganized.. ...

Q1. What quality tools would you use to focus on the disorganization?

Many picks from stock are found to be wrong and when you do audit of 500 picks you get the following data

1. 10 are labeled wrong from the supplier.
2. 12 are mis-put-away by your team Wrong bin location/wrong label.
3. 20 are pulled from stock in error.... Label is correct.
4. 30 have the wrong quantity picked.
5. 13 are mis-packed into a shipping consignment.

Q2. What is the total % defect level for the 500 picks?

Q3. What chart would you use to prioritize your focus on the solution?

Q4. How would you organize an improvement project to focus on the wrong quantity picked?