Mapping, analysis, optimization and workload of the "Good Sorting" logistic process. The case of Xylem Inc.

The following paper aims to outline a company project focused on mapping, analyzing, and optimizing the internal logistics flow, particularly in the finished goods sorting area. It illustrates the preliminary steps taken to create the flow chart of the process under examination, the current workload sizing, and the implementation of the identified improvement opportunities. The document was prepared during the internship carried out at the Xylem-Lowara production site in Montecchio Maggiore, a leading metalworking company in the field of hydraulic pumps and water control and movement systems. Initially, a brief explanation will be provided on the advantages of mapping a company process in detail, presenting the techniques currently available for this activity. After introducing the problem statement and outlining the structure of internal logistics, all the steps followed to achieve the company's objectives will be comprehensively presented. The basic steps will outline how the process diagram of the flow under consideration was created, how the number of resources required for its efficiency was estimated, and how the effort-benefit matrix was developed. This matrix documents all the improvement opportunities identified during the various project phases to enhance it. Finally, the project will present the design of a calculation tool that determines the weekly workforce requirements based on future production forecasts, demonstrating a practical application of the project’s findings. Thanks to this project, it is demonstrated how systematic process mapping and analysis can lead to significant improvements in logistics efficiency, providing a model that can be applied to other areas within the organization.