The root problem we tried to fix was the process of receiving product and getting it stocked on the shelves immediately at the location. The variables we considered include cost, stockroom layout, company standards, ADA regulations, and material handling equipment. The process of collecting and evaluating data was completed by analyzing a variety of in-store reports that provided different types of data leading to an optimal solution.

1. Improving Product Flow at Meijer
(Bolingbrook)
Students
Nick Goodell
Jay Desai
Zeus Ceniza
Maria McKiever
Advisor: Dr. Quintin L. Williams Jr ( Dr.Q )
Plant Layout and Material Handling (IE463) Term Project
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2. Content
▶ Introduction
▶ Process Map
▶ Root Cause Analysis (Fishbone Diagram)
▶ Current Layout
▶ Backroom Pictures
▶ Material Handling Equipment at Facility
▶ Tree Diagram
▶ Contingency Diagram
▶ Solution
▶ Proposed Layout of Backroom
▶ Expected Outcomes
▶ ADA
▶ References
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3. Introduction
▶The first Meijer location in the Chicago region
opened in 1999 on Weber Road
▶ The receiving space consists of 13 dock doors, 17
aisles and thousands of products
▶The root problem we are trying to fix is the
process of receiving product and getting it
stocked on the shelves immediately.
▶Lack of communication between three shifts. 3

4. CURRENT STATE PROCESS MAP OF PRODUCT
FLOW AT MEIJER
4

5. Ishikawa or Fishbone Diagram
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6. Current Layout of the Backroom
Dairy cooler
14-15
Backstock
Aisle 3-11
Pallet Racks
Aisle 12-16
Pallet Racks
Miscellaneous
storage
Baler
Material
Storage
Grocery Backroom
6
AD Pallet Rack

7. Backroom Pictures
Haphazard Placement of Materials (Groceries) 7

8. Backroom Pictures (Contd.)
▶ Empty Racks
▶ Dock Doors
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9. Material Handling Equipment at the Facility
▶ Electric Forklift - Unload pallets from
truck, move heavy pallets in the
backroom, lift pallets into elevated
pallet racks
▶ Electric Pallet Jacks - Move heavy
pallets in the backroom only
▶ Manual Pallet Jacks - Move pallets to
and from the sales floor for stocking,
rearrange pallets in backroom
▶ Pallets - Separate, sort and store
product on pallets
▶ L-Carts - move and store ad products
▶ M-Carts - move and store back stock
products
Electric Pallet Rack
Electric Forklift
L-cart
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10. Tree Diagram
Shift Change
Communication
3rd shift needs to
pass off unfinished
work
3rd shift may need
to add workers
Organization
Untouched product
is put in a specific
section
3rd shift needs to
organize what still
needs to be done
Stocking
Some aisles are
skipped due to lack
of time
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11. 11

12. Cost Analysis
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13. Solution
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▶Redesigned layout
▶First shift task reassignments
▶No communication necessary
▶Costs, feasibility, investment

14. Proposed Layout of the Backroom
Dairy cooler
14-15
Backstock
Aisle 3-11
Pallet Racks
Aisle 12-16
Pallet Racks
Un-stocked Live
Load
Baler
Material
Storage
Grocery Backroom
14
AD Pallet Rack and Miscellaneous

15. Expected Outcomes
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▶Product stocked immediately
▶Decrease in hole count
▶Increase in sales
▶Improved storage organization

16. ADA at MEIJER
▶40% goal
▶US Business Leadership Network
▶90% rating Disability Equality Index (DEI)
▶Best Places to Work for Disability Inclusion
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17. References
▶ Facilities Planning (4th Edition) by James A. Tompkins, John A. White, Yavuz A.
Bozer, J. M. A. Tanchoco, John Wiley & Sons Ltd, UK, 2010.
▶ Total Quality Management by L. Suganthi, Anand A. Samuel, PHI Publication, 2004.
▶ http://www.meijer.com/
▶ http://newsroom.meijer.com/news/meijer-recognized-as-a-best-place-to-work-
for-disability-inclusion
▶ https://www.payscale.com/research/US/Job=Systems_Administrator/Salary
▶ http://sfadiningrd.blogspot.com/
▶ PTC Creo 4.0 Student Version
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18. Questions
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19. 19