The aim for the FRT is to reveal how the system should work when the con- straints have been exploited and the changes are implemented. The FRT is an excellent tool to use to over come residence to the change, thanks to that it is easy for anyone to understand the positive outcome from the change. The idea is to develop a reality tree with the base of the four changes that were identified from the ECs and by that remove the Undesirable Effects. The CRTs that were establish earlier was a bit messy and even hard to understand due to that they did not have a clear start or ending because the warehouse was in bad shape and had no strategies. The FRT will be design as it represent one working day even though the arrival of orders is continues happing during the day. Thus, as the system will be in the future it has two main entry points and one end.
The system start by orders arrive and that they get sorted by the new algorithm that make sure that the resources get utilized. On a normal day
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there are five workers in the warehouse, the idea is that two workers are responsible for one saw each. They load the saw with the first order that should be cut and during the time the martial is processed the worker can collect the rest of the material that should be cut in that saw and queue them. By queuing all the material the set-up time between the cuttings are kept to a minimal. One worker is responsible for the water jet cutting machine so his job is to get that going as fast as possible. When the saws are working the employees are suppose to start picking the rest of the first order and make sure that when the cutting process is done it will go fast to pack the order. If there is time before the cutting is done the worker will continue picking the next order. By doing this the labors are more efficient utilized. Of course he goes on picking orders until the all materials are cut in the saw. The saw machine should be working all the time until there are no more goods to cut for the day, which means that setting up the saw is priority number one. With two workers on the saws and one on the water jet leaves two people to pick the smaller orders, mainly picking from the new FPA. If there is an order with small goods in small batches everything should be picked from the FPA, if there is a large batch of items from the same material the picking should be made form the bulk box that can be placed next to the packing station. Ones the order is packed for any of the workers he is supposed to book the transport and put the order in the dedicated area, this will prevent workers from leaving orders on the scale. The dedicated area is divided after transport companies.
During the day new goods arrive and the policy with the new system is that one of the workers, that are not responsible for the saws, can receive the goods and have to place it in the new rack and mark it with its specifi- cation. When the goods are placed in the rack he can return to the work he was doing. In the end of the day when all orders have been pack and there is no more new arrivals the workers have three main activities to do. The first one is to make sure that the FPA holds enough material so it would not stock out the following day. The second is to make sure that the arriving goods rack gets empty and all goods goes into their real location. The last thing that should be done if possible is to set up the queue for the saws for tomorrow. This will increase the utilization of the saws the following day and decrease the transport the worker need to do the following day so he can pack even more orders or use himself to more valuable work than transporting. Figure 4.12 shows the FRT.
Now when the Future Reality Tree is developed a picture of the future system is visible. All involved, manager, stakeholders and employees can get an understanding of what will happen in the future and see why some
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changes are necessary today. Now the question How to cause the change? arises in everyones head. Thats why the next tool was developed, the tool is called Prerequisite Tree. The Prerequisite Tree will show and explain what work is need to be executed to be able to implement the new solution and by that occur the new system to start working.