Pick, package and dispatch a customer order by rail

What is going on

Gippsland Box and Carton has ordered 42 reels of 140 gsm fluting at 2,100 millimetre width for rail dispatch on Friday. The reel store holds reels from three production days, and three reels from Monday's run were edge damaged by a forklift and downgraded, so they must not be picked. Each reel must be checked against the order, wrapped, labelled with the reel identification and customer details, and staged for the rail wagon with load restraint to the rail rules. The laboratory has issued the certificate of analysis for the lot. The Finishing and Warehouse Manager wants the stock movement and dispatch recorded before the wagon leaves.

Your brief

Pick the correct reels for the order, package and label them to the site standard, stage and restrain them for rail dispatch, prepare the dispatch paperwork including the certificate of analysis, and record the stock movement and dispatch in the Production Shift Log.

Work through it

You do not need to do it all. Doing a few of these will show you what the work is like. Your ticks and notes stay on this device.

• Read the Quality Policy sections on specifications, testing and nonconforming product and explain how you will make sure no downgraded reel is picked for a first quality order.
• Review the Incident and Hazard Register entry for the forklift contact with reels and the shift log record for Monday's finishing shift, and list the reel lot that must be excluded.
• Prepare a pick list of 42 reels with their reel identifications, production date and lot, and describe how you checked each reel against the order specification.
• Describe the wrapping and labelling steps for each reel, including the information that must appear on the label and how damaged wrap is dealt with.
• Plan the staging and loading of the reels for the rail wagon, including the order of loading, the restraint method and the pre-load check of the wagon.
• Prepare the dispatch paperwork: consignment note details, reel list and certificate of analysis reference, and check they match each other.
• Create a Production Shift Log record for the finishing area showing the reels dispatched, any reels rejected during picking and the closing stock for the grade.
• Identify two hazards in the reel store and dispatch area and the controls you will apply, and record any new hazard on the report form.

What someone in this role would produce

• Pick list with reel identifications and lot exclusion
• Packaging, labelling and load plan
• Dispatch paperwork set
• Production Shift Log record for finishing
• Hazard identification with controls