Do not count the bulk cage while door 3 is unloading
“Do not run the bulk cage count while door 3 is still unloading. Half the pallet is on the floor and half is in the rack. The number comes out wrong every single time.”
Grave slotted the 2-inch family into the retired home A-14
Putaway posted 36 EA to A-14 at 03:02. The current home is A-14-03. The counter walked one slot and the rest of the family was sitting a bay over. A −6 on this family has matched slot drift four times running.
Confirm it
· Walk A-14 and A-14-03 and count both slots on the same sheet
· Pull the 03:02 putaway scan and read the slot it accepted
· Check whether the scanner still offers A-14 on this item
Kill it
· A-14-03 is empty and A-14 holds exactly what the system says
12 EA sat staged on the floor during the unload at 03:02. Product split between floor and rack reads as a short no matter who counts it.
Confirm it
· Check the door-3 unload window against the 22:40 count stamp
· Ask the counter whether floor staging was in scope
Kill it
· Door 3 was closed and nothing was staged when the count ran
Rank 4Possible · 3/5
Case-pack of 12 posted as eaches
The vendor ships 12 to a case. Half a case is six pieces, and six is exactly the miss. A UOM slip on receipt looks identical to a physical loss.
Confirm it
· Read the carton label UOM against the item master
· Recount the slot by case, then by each, and write both numbers
Kill it
· Carton and item master both read eaches on PO-8841
Rank 5Long shot · 2/5
Pick short from the wrong slot, system never adjusted
WAVE-119 pulled 12 EA from A-14 and confirmed short at pack. If the short was never posted, on-hand stayed high on paper.
Confirm it
· Pull the WAVE-119 short confirm and check for an adjustment
· Ask pack what they shipped
Kill it
· The short was posted the same shift
Architect check
· Goal restated: explain the −6 and install one procedure that stops the repeat.
· Missing info: no photo of A-14 vs A-14-03 in this demo seed.
· Assumptions: item master UOM is each; vendor pack is 12; A-14-03 is the current home.
· Weakest point: two plausible causes (slot drift and live-unload count) can both be true. The procedure covers both instead of forcing a single villain.
Tonight's procedure
A-14 family putaway and count lock — Valley Gas 2-inch
Every Valley Gas receipt · every A-14 family putaway · before any A-14 count
1Receiver
Before scanning a Valley Gas pallet to the PO, find the heat-treat stamp on two pieces per layer.
Fail if: Stamp is missing: hold the dock, do not close the receipt.
2Receiver
Confirm the vendor pack. If the label says 12/case, post cases and eaches the way the item master reads.
Fail if: System UOM and carton UOM disagree: call the supervisor before close.
3Putaway
2-inch Valley Gas homes to A-14-03. A-14 is retired.
Fail if: The scanner offers A-14: override to A-14-03 and log it.
4Grave lead
Do not start a bulk or A-14 family count while door 3 is unloading.
Fail if: Product is split between floor and rack: wait, or count only the settled rack and mark the rest staged-not-counted.
5Counter
Blind count the location.
Fail if: Variance is ±6 or ±12 on this family: do not post an adjustment. Open Autopsy.
6Supervisor
Walk the retired slot A-14 and the floor staging. Photograph both.
Fail if: No photo attached to the CC record before the handoff.
7Day lead
Next shift huddle: one minute on the A-14-03 home and the heat-treat look.
Fail if: The handoff box is not checked.
Train tonight Jamal Rivers walks grave through steps 3 and 4 at the 22:00 huddle — one minute at the cage, not a classroom.
Coaching card
A-14 is not the home anymore. If the gun offers A-14 on 2-inch Valley Gas, stop and send it to A-14-03. That six-piece miss is the old slot, not you being sloppy.
Close it out
Pick the primary cause before you close this one.
Promotes the rule, drafts the procedure, and closes NEW. Fenyx does not post adjustments.
