Re: Reduction of product on floor?
What you are refering to is call "apparent efficiency" which is not "true efficiency".
Classic example. A supervisor goes to his manager and says " We are doing super. We just built 125 pieces with 10 people, thats 25 pieces more than we normally do". The manager say's, why is that great? We are supposed to build only 100 pieces. You built 25 pieces too many. If you are able to build 125 pieces with 10 associates, then you should build 100 pieces with 8 people.
(125/10 = 12.5 pcs per person. 12.5 X 8 people =100).
In this first case, over producing what you cant sell is very expensive and wasteful. You just building, handling, ordering and storing material that's not going out the door.
When you say 2580' of walk time in a day has been saved, did you reduce your manpower? If the answer is 'NO" then your savings is "apparent" not "true".
If it eliminated overtime, then the savings is "true".
If you eliminated the need for a fork-truck, then the savings is "true" (lease of the cost of the truck is the savings)
Please don't try to grab money that isn't really there.