CooperVision
A contact lens pioneer for decades, CooperVision has become the fourth-largest contact lens maker in the world and the number one manufacturer of toric lenses. CooperVision distributes high-quality lenses virtually everywhere contact lenses are worn, with a special focus on premium specialty lenses from their facilities in 12 countries across five continents.
Applications: Discrete Order Picking, Multi Order Picking including Cluster Picking, Batch Picking
| Objectives | Results Achieved |
|---|---|
| Improve overall productivity | Average hourly pick rates more than doubled from 130 lines to 290 lines per hour |
| Balance headcount to optimum levels | Reduced the number of order checkers as a result of increased accuracy in order picking |
| Reduce errors with greater accuracy | Reduced error rates by 75-85%, from 7-8 picking errors per cart to a maximum of 2 errors per cart |
| Save on labor cost through increased worker productivity. | Decreased overtime hours by 83%, while overall order volume increased by 10% |
| Reduce worker ramp up to standard proficiency | Reduced training time of new pickers from several weeks to several hours. |
| Improve productivity of experienced workers | Development of a “super user mode” above “expert mode” established even higher pick rates |
| Leverage real-time information on productivity | Used individual worker productivity reporting to implement incentive-based pay structures |