Arbonne International
(in 1991)

Arbonne International, headquarters, El Toro California

I went to work full time at Arbonne International in November of 1988 at the invitation of it's president, Petter Moerck. 

I was first introduced to Arbonne by a friend of a friend, who came home crying (literally) one evening when I was visiting. "What's the matter?", we asked, and were answered with a deluge of worry, problems and concerns, all relating to the computerization of her company. At her request I met with it's president. We arranged to visit Arbonne after hours, there to look into the secretive work their computer programmer had been doing. 

Their primary computer was a Compaq 286: 32 megs of Ram, PICK operating system, an 80 meg hard disk, a 60 meg backup tape, and seven (7) serial ports connected to Televideo terminals acting as order entry workstations. A single TI dot matrix printer was used to print orders which were hand carried to the warehouse for fulfillment. Additionally the programmer had purchased 9 Macintosh's and a single laser printer, placed them on desktops and connected a few of them together with AppleTalk. 

Their programmer had convinced the company to use Macs as workstations connected to the Compaq PICK system; Order picking tickets were to be printed in the warehouse and reports were to be printed on the Appleshare laser printer. The company President was concerned that the programmer was failing to accomplish this, his wiring of the building to support it was incomplete and the deadline to do so had come and gone with no completion. The programmer had become highly defensive and the entire company was distraught.

I located and hired Jonathan Sisk, an erudite PICK author and training guru who, surprisingly, lived just a few miles away. Together with the President we invaded the programs of this 'programmer' one evening, and learned that little to no progress had been made toward achieving the goals he had promised the company. Unfortunately, Arbonne had devised it's marketing plans around this vision and had sent PR out promoting the new system 'to the max'. It was two weeks from the scheduled annual sales meeting. No wonder my friend's friend was crying. 

The President asked me if I could help, and I told him I, with Jonathan's support, would do what I could.  The next day Jonathan recommended (and I hired) several accomplished programmers. So began a process of re-engineering the company, its sustained and sometimes explosive growth, and my start down the path toward becoming a Professional Project Manager.

When I first visited, Arbonne had but 8,000 square feet and 13 employees. When I left, It had relocated to an approximately 40,000 sq. ft. facility and had 45 employees. As Operations Coordinator, I was intimately involved with every aspect of the company's activity: phones, storage racks, records storage, employees schedules- and both computers and custome software applications.. I had 36 ports on a C.ITOH minicomputer running PICK when I left, and all of the Macs had access to it, fulfilling the earlier vision.

My biggest effort was a revision of the order fulfillment process. In my first year, product was stored on shelving like you find in a garage, and orders were filled from hand carried picking tickets by Spanish (mostly from Argentina- Hola Mirta!) workers pulling from the shelves into various sizes of cardboard boxes. They sat down with their box-full at a folding 4X8 table and reviewed the order. Another person would finish packing the order with Styrofoam peanuts (which I replaced with biodegradable starch and recycled paper fillers, ), tape, weigh and label it for shipping.

.It wasn't all roses however. In 1993, just 12 days after making the *first payment* on our new home, Arbonne laid me off. Two weeks later, they laid off my wife. and about a third of their staff. The California recession of 1993 had arrived. 

The pictures on this page are of the picking line shortly after it was installed

picking line start


The 'garage-style'  shelves which in previous years had held product for order fulfillment, were replaced with the above. The Product line was distributed across several people; picking tickets were sorted by the computer to order the products as they occurred on these racks, and the distribution of products across the racks was determined by sales volume- assuring uniform work for each of the order fulfillers.
Product was picked into recycled cardboard trays (like egg trays) measuring 1 ft X 1 ft.. This allowed our  shipping boxes to be standardized, cutting costs.

I designed and specified this this as well as the phones, voicemail, computers and software of the company. Twice I was asked to create a complete and thorough analysis of the workflow of the company. The first was for Petter Moerck, and the second, two years later, for Steve Koshen, both company presidents.

As an order moved down he picking line items were checked off as they were filled; as stock was consumed through order fulfillment, stock was replenished from behind these racks by warehousemen.
picking line middle
picking line inspection
The last person on the picking line was the order checker- a person who would randomly stop orders to make sure that the products ordered were a match for the products picked.
When order picking was complete and had passed inspection, an order moved to one of two shrinkwrap stations where it was surrounded with plastic wrap and then passed through a heat tunnel.
shrink wrap stations
heat tunnels
The plastic collapsed and tightened itself in the heat, forming a rigid and shippable collection of product.
Trays of product were gathered into order collections . A single tray measured 12 inches on a side. Multiple trays collected six high before an order was split into multiple boxes for shipping.
shrink tables
paper dunnage system
Various methods of packing were used as dunnage; the most successful of these were a paper corrugator, seen here in grey. I peeled a heavy paper from a roll, corrugated it with dimples and was crumpled into partially filled boxes. This method was employed when we realized 'peanuts' would require about 12 times the storage space, since the paper was only crumpled on demand.
A PICK programmer shown here, obviously hard at work on a difficult problem..
John Bohner
Jack Corey supervises training
Software revisions were created as marketing developed campaign strategies, typically very four weeks. As each new marketing campaign approached, sessions like these occurred for each work shift.

 

 

 

 

 

 

 

 

 

 

 

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