Process Improvement

TWO Main Categories

  • Location (Floor)
  • Items (Bins, Documents, Racks)

TWO Main Categories – Part One: FLOOR

  • Location (Floor)
  • Items (Bins, Documents, Racks)

Floor areas where need colour coded:

  • Warehouse – Picked WOs
  • P&C
  • Mech/Elect – Sub-assembly
  • Mech/Elect – Final Assembly ( Green Floor )
  • Integration ( Green Floor )

All of this areas can be the same colour (Racks Parking Lot), we just need to identify the racks storage location. Our work flow should be in ONE DIRECTION.

TWO Main Categories – Part Two: Items

  • Location (Floor)
  • Items (Bins, Documents, Racks)

3 Type of items that needs colour coded.

  • Document
  • Bins
  • Racks

Each BAY already has their own colour, so we don’t pick the colour for the machine. When we have a machine sales order, we decide where to put the machine, then we know which colour code will be assigned to this machine.

Projects Flow Plan ( Which step to decide the machine location?)

Document and Bin are related, so if they are under the same work order, they will be the same colour. Racks depends on the Bins. For example: if MACHINE-A is plan to store at BAY 1 and BAY is red, all MACHINE-A documents and bins will label RED. AND if technician going to put the bin to a rack, the rack has to be labeled RED.

To be more efficient, we can use colour sticker instead of colour document holder. Colour sticker can also be used on BINs and Racks. See example below:

3 Type of items also have 3 categories:

  • Sales order
  • Stock order
  • Machine build order (depends on the BAY)
  • (R&D?)

We only need to decide the colour for sales order and stock order, all BAYS already coloured.

Signs of colour code will install in multiple locations

Picked Racks Area

Remove one cable rack. Cable will store in other location. This only for cutting. We can cut few set of cut to length cable.

  • Incomplete WO’s with SHORTAGE can label with different type of sticker
  • Sub assembly area is for Ongoing (incomplete) WOs. Complete Sub-Assembly WO should go to Final Assembly.

Above solutions will solve the issues which highlighted in green.

Lets move on to next issues: Build plan changes

When do we need build plan changes? When the following issues happen:

They are not a big issue before. Why now become a big issue?

All these are accidents. Other departments will try to prevent it from happening, but when it happens, we need a plan to due with it: Events trigger system

  • Late shipment
    • Sage have the FIRST AVAILABLE DATE, we should review it every day
    • Who will know if it’s late?
    • Are we reviewing all the expecting shipment?
  • Damage shipment & missing shipment
  • Part missing
    • Who should inform?
    • We will know the part is missing during picking, but who should involve?
    • How do we know the status?
    • If we have budge, can we order a new one right away instead of waiting?
      • Lead time, cost.
Review availability and update build plan




Late (expecting date)
Late (expecting date)
Affect assy?
Event Close
(Procurement Internal)
Event Close…
Review Build
Event Close
(will trigger new event base on new date)
Event Close…
New Build
Follow Up

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We can use Excel Or a whiteboard to list all events.


Agile Project Management

LEAN, not only physically.

We have all the information in sage, how can we use it more efficiently

Tools Can help

Total cost of project:

Total: $256 + $84 + $97.74 = $437.74

Others – FYI

  • Instructions
  • Cut to lengths
  • Progress tracking

Issues & Solution Ideas

Parts’ Life Cycle

Parts Receive
Parts Receive
Attached Label
Attached Label
Update on Sage
Update on Sage
Put to Inventory1. Miss count whenreceived2. Wrong BinPicking1. Pick wrong part2. Miss3. Extra4. ShortageMFG1. Pick wrong part2. Miss3. Extra4. Shortage
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The common of these errors: cause by human