Process Improvement

Our Goal:

  1. Accuracy
  2. Efficiency
  • Reduce human error
  • Reduce routine work

Section 1: Procurement

Issues

  • Late shipment
  • Missing shipment
  • Damage shipment

Solution

  • Communication
    • Procurement -> Warehouse -> MFG
  • Warehouse should champion
    • WO Replenishment
    • Expeditiously – HOW????
  • Robust Planning
  • Robust safety stock strategy
    • LT
    • Avail
    • Cost
    • Criticality
  • Strong vendor mgmt

Section 2 – Quality Inspection

Issues

  • NCR fail
  • NCR time to close

Solutions

  • Communication
    • QC -> WH -> MFG/Procurement
  • WH/MFG to prioritize picking list

Section 1 and 2 solution: communication

Idea: events trigger system

Late (expecting date)
Late (expecting date)
Yes
Yes
No
No
MFG:
Affect assy?
MFG:…
Event Close
(Procurement Internal)
Event Close…
MFG
Review Build
Plan
MFG…
Event Close
(will trigger new event base on new date)
Event Close…
MFG
New Build
Plan
MFG…
Procurement
Follow Up
Procurement…

Viewer does not support full SVG 1.1
  • How do we know if the shipment is late?
  • Who & How to look after it? Who initiate the event trigger?

Solution Options:

  1. Manually: Excel
    • Export data from Sage
    • Functions
  2. NCR system, Basecamp
  3. Custom CMMS

Section 1 Solutions

  • Communication
    • Procurement -> Warehouse -> MFG
  • Warehouse should champion
    • WO Replenishment
    • Expeditiously – HOW????
  • Robust Planning
  • Robust safety stock strategy
    • LT
    • Avail
    • Cost
    • Criticality
  • Strong vendor mgmt

Section 2 Solutions

  • Communication
    • QC -> WH -> MFG/Procurement
  • WH/MFG to prioritize picking list

Example: Custom CMMS

Sys01

Sys02

Sys03

Questions:

Section 3 – Material Relocation

Issues & Solution Ideas

  • Starts in wrong location
    • WH shop – cycle count
    • Rack labeling
  • Lost parts
    • Why
    • Who to champion
    • Communication – informs WH, MFG, PR
    • Cycle count
  • Material movement – picking
    • WH – WO schedule
    • WH SOP
    • More WH people
    • Improve picking speed
    • Improve cycle count speed

Parts’ Life Cycle

Parts Receive
Parts Receive
Attached Label
Attached Label
Update on Sage
Update on SagePut to Inventory1. Miss count whenreceived2. Wrong BinPicking1. Pick wrong part2. Miss3. Extra4. ShortageMFG1. Pick wrong part2. Miss3. Extra4. ShortageViewer does not support full SVG 1.1

The common of these errors: cause by human

Solution: Barcode System

  • Datalink
    • How is it connect to Sage.
      • API?
    • Login users – limited?
    • The IT company setup Sage?
  • WASP
  • Zebra

Issues & Solution Ideas

  • Starts in wrong location
    • WH shop – cycle count
    • Rack labeling
  • Lost parts
    • Why
    • Who to champion
    • Communication – informs WH, MFG, PR
    • Cycle count
  • Material movement – picking
    • WH – WO schedule
    • WH SOP
    • More WH people
    • Improve picking speed
    • Improve cycle count speed

Other Idea

SOP execution

  1. Train employees
  2. execute the SOP step by step