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I have often reminded students and colleagues that, as we diagram the flow of products and orders through manufacturing and warehousing processes, it is important to capture the reverse flow of empty containers. In handling units moved, this flow can be as great as the forward flow.
Another frequently overlooked, but significant, flow is that of shipping cartons making their way to the first picking location.
There seems to be a prevailing attitude that anytime a picker, or stocker has some time available, it should be used to make a supply of shipping cartons for use during busy periods. Unfortunately, empty boxes are bulky and don’t stack very well. This common practice usually leads to messy stacks tucked into every available corner.
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ABOUT THE AUTHOR
James M. Apple, Jr. is a Director in The Progress Group. Prior to co-founding The Progress Group in 1991, he was a Partner with Coopers & Lybrand's SysteCon division. During 1992-1995 he served as a Senior Systems Advisor with Vanderlande Industries, a major conveyor and systems provider in Europe.
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