DCSOLUTIONS ‹ CONTINUED FROM PAGE 175
tems were in line for an upgrade. “Every year we look for ways to improve our processes,” says Barb Wood, senior manager, returns operations for L.L. Bean. “Last year, we focused on the material flow.” One method the company considered was to centralize package opening upon receipt. As the concept moved into the pilot stage, L.L. Bean sought feedback from its reverse logistics center employees. That’s when the process began to “morph into something more,” says Wood. “We decided to try the idea of dedicating single employees to handle each account every step of the way, eliminating non-value-added steps in the process.” With this fairly detailed homegrown solution in the works, L.L. Bean looked for a partner that could provide the equipment needed to get the job done, along with the engineering exper- tise to implement the processes. “We considered three different vendors,” says Wayne Steele, L.L. Bean’s industrial engineering supervisor, “and selected VARGO Companies.” VARGO Companies is comprised of three strategic compa- nies located in Ohio, California, and Texas, and specializes in system integration, software solutions, and materials handling equipment. It set itself apart from the other vendors L.L. Bean considered because it presented a solution that would increase the retailer’s flexibility to meet the challenge of flowing prod- uct to 160 processors, and ensure minimum work-in-process. VARGO developed a simulation model that spelled out, in detail, how the system would work. “VARGO’s methodology was different than other vendors we considered,” says Steele. “The intelligence within the equip- ment was higher, and the documentation was in place to back it all up.” L.L. Bean approached VARGO with well-defined objectives. “The company knew what it wanted, but wasn’t sure how to get there,” says Carlos Ysasi, vice president of systems engineer- ing for VARGO. CONTROLLING THE RIVER L.L. Bean’s most pressing challenge was controlling prod- uct flow. “A river of product was rushing in the door, and the company had no control over how it was delivered to the pro- cessors,” says Ysasi. “So VARGO took control of the product flow to provide L.L. Bean the right amount of product at the right time.” VARGO’s solution incorporates a dual-loop system controlled by flow meters and proportioning dividers. Automatically deliv- ering product avoids delays caused by processing workloads, and ensures that all workstations receive product on time. At the center of the process are VARGO’s dynamic workflow control system and product distribution conveyors. As returns come in the door, “spreaders” convey them to workstations. Automatic speed control transfers product via a “waterfall” that cascades product from one conveyor to another.
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