From circles to sticks to scales – the evolution of counting small inventory at DLA Distribution

NEW CUMBERLAND, Pa. -

Everyone knows that Defense Logistics Agency Distribution works with large items like engines and propellers, but the small items like nuts, bolts and washers are just as important to the warfighter.

Mandy Brechbill, materiel readiness division chief for DLA Distribution, said the process of breaking down large quantities of these items even further was labor intensive, but just as important.

"There are times when a customer would need just one," said Brechbill. "But often when you go to pick one, you don't just pick it and walk away with it like at big hardware stores, you have to go get the one item, put it in a baggy, reprint the label, get that ready to ship."

What ended up happening said Brechbill is a lot of times people will split the bag up, dump them out, take what they need, so they have that label and walk away with it. When you are left with that, to either repack, to count, to do any kind of work on it, it is a lot of manual labor to sit and count all those to account for the material.

Most important, she said, DLA Distribution audit readiness was looking at the amount of labor as a failure point with having to do a physical count rather than relying on equipment to do it.

A scale pilot was initiated to improve counting accuracy and efficiency. Scales help with trying to do inventories, repackaging and receipts, because workers do not have to sit and do a manual count.

"Once we saw the industry practice of using scales, we were able to do a proof of principle, then bring the scales in for an inhouse demo. We went to a pilot practice for about six months. We demonstrated to the workforce how to use the scales to count and weigh the material to equal amounts," said Brechbill.

The process of calibrating material weight begins with a single item, said Brechbill.

"You put one on the scale and get the weight for it, say it is one ounce. If you need ten, you already know that one is an ounce so if it is ten then it's ten ounces. Same method applies if you need another amount," said Brechbill.

"We ran the pilot to make sure that the scales performed how we thought they would. And it worked. They are now being used in receiving inventory, preservation/packaging/packing and marking, stock readiness, and pack and pick areas."

Scales proved to work very well, much better than the circle, said Brechbill.

"Before scales we tried using the diameter of a circle for counting. We would draw a circle, put items in the circle, and decide that the number of items that fit in a circle was 100. Which wasn't that accurate."

Then there was the stick.

"The stick was a certain length, and nuts or washers were threaded over the stick like a skewer. Depending on the stick length you could tell how many items would fit. It was more accurate than a circle, but you can only use the stick for certain items, so it had limitations," said Brechbill.

Scales proved to be the most accurate and efficient way to work and is an industry standard.

"It has been an evolution of trying to make our job easier. We went from circles to sticks to scales. And scales have proven to work well," said Brechbill.

"Some scales have a calibration schedule. You cannot move them. They must be on a stable platform. The scales that we are using are infinitely easier. You can pick them up. You can walk them around. You can take the scales to any location and do that work," said Brechbill.

Using scales has diminished turnaround times to at least 20% or more, she said, because the process is infinitely easier, faster and improves accuracy.

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