Work Instruction Logistics Insights Corporation Version 2.0
WI-50 CMC DOCK INSTRUCTIONS January 12, 2006
This section briefly describes how to operate daily processes for the CMC
Equipment:
1. Hi-Lo
2. Pen/Pencil
3. Clipboard
4. Required Picks Manifest
5. Labels
General Guidelines:
1) Follow all lift truck regulations.
2) Perform inspection via Forklift Checklist at the start of your shift.
5) Any additional duties that need to be completed and/or may be requested by the Supervisor.
6) At the end of each shift park Forklift in designated parking area
Instructions:
Inbound
1) Pull the dock plate, check the trailer for any visible damage, and ensure the trailer is chocked.
2) Unload and place containers to designated storage lanes, re-load to an outbound trailer OR, stage to assigned sorting areas. Refer to CMC Dock Set Sheet / Layout.
Note: While unloading, check for damage to containers/racks and inform a Supervisor of any identified problems. The Supervisor directs the action to be taken (i.e. move containers to the CMC Damage area & tag)
3) Once the trailer is empty, pull the dock plate, put the safety chain up at the door, and inform a Supervisor of the empty trailer number.
Outbound
1) Pull the dock plate, check the trailer for any visible damage, and ensure the trailer is chocked.
2) Load containers/racks, ensuring applied labels face outward (i.e. visible when entering the trailer), per the Picklist requirements or Supervisor instructions.
3) Log quantities loaded onto the Picklist for LTL Picks OR onto the Destination Tally Sheet (Trailer Load Repot) for Truckload Picks.
4) Upon completion of each outbound trailer load, note the trailer number, cube % and Dockman name (or initials) on each Picklist.
5) Ensure the outbound trailer is loaded safely and is secured so as to prevent any shifting of containers/racks/totes while in transit.
Outbound (continued):
6) Pull the dock plate; put the safety chain up at the door, and forward completed Picklists and/or destination Tally sheet to CMC Supervisor.
Sorting
1) All sorting is performed in the designated sorting area.
2) Identify each container/tote type by the ID number listed on the side of each empty tote: Example: SD151208, SC151208 / SC = green, SD = gray).
3) Remove all trash and cardboard from the containers/totes and dispose of in the appropriate receptacle.
Ø NOTE: Visually inspect each container (hinges and clips), and check for any structural damage throughout the sorting process.
4) If container is a KD/KC, collapse container down prior to moving to storage location.
5) If containers/totes are Supplier-specific (i.e. Delphi or Delco), place them in the designated areas where pure Supplier-specific skids are consolidated.
6) Turn all generic containers/totes upside-down onto “good or working” seat-belted pallets (i.e. UP484507’s).
Note: “Bad or non-working” seat-belted pallets are identified and placed in the CMC Damage area for repair.
7) Totes are packed according to the GM standards listed below:
151208 36 per skid 242309 20 per skid
241508 36 per skid 242311 16 per skid
241510 24 per skid 242315 12 per skid
241515 18 per skid 321508 24 per skid
481508 15 per skid
8) Once a skid has been standard packed, cap the skid with a “good or working” seat-belted pallet. CMC Dockman will then put to storage or use for outbound pick.
Picking
1) Pick the “odd numbers” against the standard pack for each Picklist and stage the skids in the Sorting area for loading.
2) Tag each skid by applying a label to the AIAG label on the tote that is located on the upper right hand corner of the skid. For any other containers (baskets), place label on AIAG label.
Picking (continued):
3) Record all quantities to the Picklist. Load containers to the outbound trailer, and forward Picklist to CMC Supervisor upon completion.
Container Stacking Requirements
CONTAINER TYPE / HEIGHT / CONTAINERS PER SKID / CONTAINER TYPE / HEIGHT / CONTAINERS PER SKID3013 / 3 / N/A / BLUE 3804 / 4 / 16
4043 / 5 / N/A / BLUE 5115 / 5 / 30
4498 / 4 / 12 / BLUE 5126 / 4 / 24
6434 / 9 / N/A / BLUE 5166 / 4 / 24
22165 / 3 / N/A / BLUE 7020 / 4 / 24
22695 / 6 / N/A / BLUE 7020 / 4 / 24
22882 / 4 / N/A / GREEN 5312 / 8 / 48
22923 / 3 / N/A / KC323025 / 7 / N/A
23051 / 4 / N/A / KC323034 / 7 / N/A
23052 / 4 / N/A / KC484525 / 9 / N/A
23210 / 5 / 25 / KC484534 / 9 / N/A
28436 / 3 / 15 / KD323025 / 7 / N/A
28615 / 2 / 12 / KD323034 / 7 / N/A
30043 / 3 / 12 / KD484525 / 9 / N/A
31285 / 6 / N/A / KD484534 / 9 / N/A
31530 / 3 / N/A / OR-35534 / 8 / 48
35561 / 7 / N/A / SC/SD151208 / 3 / 36
0927 / 4 / N/A / SC/SD241506 / 8 / 48
26102/26103 / 3 / 18 / SC/SD241508 / 5 / 30
AHB41285 / 4 / N/A / SC/SD241510 / 4 / 24
AHB52707 / 4 / N/A / SC/SD241515 / 3 / 18
AHB52711 / 2 / N/A / SC/SD242309 / 6 / 20
AHB58977 / 4 / N/A / SC/SD242311 / 4 / 16
AHB59875 / 2 / 45 / SC/SD242315 / 3 / 12
BLACK 1076 / 4 / 32 / SC/SD321508 / 5 / 20
BLUE 1052 / 4 / 24 / SC/SD481508 / 5 / 15
BLUE 132 / 4 / 16 / SM BLUE/RED / 3 / 36
BLUE 30670 / 4 / 24 / SM ORANGE / 3 / 36
BLUE 3091 / 4 / 24 / UP484507 / 20 / N/A
BLUE 31886 / 4 / 16 / VANDALIA / 4 / 24
BLUE 3801 / 5 / 20
Baling – Plastic and Cardboard
Starting with Baler empty: Mesh guard is up, and doors are open.
1) Make sure we have four large sheets of cardboard in the bottom of hopper. This will help to keep wire channels clear. Selector should be set on Auto. Close doors on baler, making sure to have all hooks connecting doors.
2) Fill baler with cardboard. If throwing large amounts of small slippery sheets in, please add four sheets of large cardboard to help bale integrity. When enough cardboard has been thrown in hopper that some is sliding out, close mesh guard and hit Start button.
3) Baler will cycle, repeat step 2).
4) If using Baler #1, When Ram is flush with outside edge, its time to bale. Using Baler #2, When arrow reads “Full”, its time to bale.
5) Throw 4-6 sheets of cardboard in top of bale. Set selector to Bale. Hit Start button. Ram will come down, compress bale, and stop. Turn baler Off. Open mesh guard. Open front doors. You must use baling wire to tie bale at three points. Feed wire through channels on bottom to come out back, then bring up to feed through to channels to come out front. Loop wire together in front and tie tightly. Check bands to be sure they are completely in channels. After this is done 3 times, there are two cable hooks on the back to hook on top plate of baler.
6) Put cardboard pallet in from of baler. Turn baler “On”. Turn selector to Auto. Hit Start button. As ram goes back up, cables will slowly lift bale so that it rolls out onto pallet.
You are now back to step 1)
7) At the end of the shift, fill baler with all plastic articles.
8) At the end of shift, put mesh guard down for safety.
Copies of this document are uncontrolled as of the date printed.
Page 2 of 4 Printed: 04/22/06