materials management - areas of responsibilities - tps model
TRANSCRIPT
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials ManagementAreas of Responsibilities
Marek Piatkowski – November 2016
Thinking win, Win, WIN
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Introduction - Marek Piatkowski Professional Background
Toyota Motor Manufacturing Canada (TMMC) - Cambridge, Ontario from 1987-1994
TPS/Lean Transformation Consulting - since 1994 Professional Affiliations
TWI Network – John Shook, Founder Lean Enterprise Institute (LEI) – Jim Womack Lean Enterprise Academy (LEA) – Daniel Jones CCM/CAINTRA – Monterrey, Mexico SME, AME, ASQ, CME
Lean Manufacturing Solutions - Toronto, Canada
http://twi-network.com
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
What is Materials Management?
Material Management is a process describing, with great precision, how every part, every component, every type of a material is managed through out a factory from the Receiving Dock to the moment when a final product is shipped to the Customer Materials Management Organization is responsible for:
1. Managing Raw Materials (Purchased Parts) – how they are ordered from the Suppliers, how they are delivered to our site, how they are received and stored
2. Scheduling Production – providing Production Lines with Production Plans. Controlling and monitoring execution of these plans to assure on-time deliveries.
3. Material Movement (Material Flow) – a well defined and standardized delivery process for moving materials between warehouses and production lines. Assuring that Production Lines have the necessary material to execute Production Plans
4. Managing Finished Goods – how Finished Product is received, stored and shipped to the Customer to meet 100% on-time-deliveries.
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Supply Chain Management
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Customer Orders
Who (which department) is responsible for taking Customer Orders?
How are the Lead Times defined? How are the “promised” delivery dates defined? How do they deal with “rush” orders? How do they answer Customer questions?
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Production Planning
Who (which department) is responsible for Planning Production? Are production plans based on a forecast or real orders? How frequently are production plans distributed? Do they change? How often? Do planners check availability of parts and machines before
planning production?
Production Planning Meetings
Production Planning Boards
Production Planning Boards
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Purchased Parts Warehouse
Is there a centralized Purchased Parts warehouse? Is it clean, well defined, Standardized and organized? Is it easy to tell who is responsible for the warehouse? Is it easy to find parts in the warehouse Is there a methodology for delivering parts to the factory?
Purchased Parts Warehouse
Purchased Parts Warehouse
Purchased Parts Warehouse
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Material Deliveries
Is there a well defined process for delivering materials to production lines?
Is it easy to understand and follow? Is it clear to understand who is responsible for delivering
materials? Are there roles and responsibilities well defined? Is it safe and reliable?
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Material Deliveries
Is there a structure to material deliveries? Are the procedures and guidelines? Is there a process in place?
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ACI PlgAssy
Short Assy
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2 hr
2 hr 2 carts800 of matl.
1 hr 45 min in a tour
Proposed value stream small components to assy. lines
12 mmAssy
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921 LiftAssy
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Assy
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Assy
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2 hr
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2 hr
T-Car Plg.Assy
ACI LiftAssy
ACI LiftAssy
ACI PlgAssy
Short Assy
2 hr
2 hr
2 hr
2 hr
2 hr 2 hr 2 hr 2 hr 2 hr 2 hr 2 hr 2 hr
2 hr
2 hr
2 hr
2 hr
2 hr
3 day
3 day
3 day
3 day
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SatPlg
Assy
846Plg
Assy
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Assy
842Plg
Assy
842Plg
Assy
Cevt.Ball
Storage“D”
Rec.Insp“A”
952Spring“B”
972Bruto rArea“C”
11 mmAssy
DAHAssy2 hr
2 hr
2 hr 2 carts800 of matl.
1 hr 45 min in a tour
Proposed value stream small components to assy. lines
12 mmAssy
I
921 LiftAssy
T-Car LiftAssy
II
I
T-Car Plg.Assy
ACI LiftAssy
ACI LiftAssy
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Assy
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Assy
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Assy
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Rec.Insp“A”
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11 mmAssy
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Sup.DAH
Supl.Rec. Insp
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Vendor
Sup.12 mm11 mm
Sup.T-Car
Janet
ACISup.
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Original Condition
Material Deliveries
Material Deliveries
Material Deliveries
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Production Line Storage
Is material stored on designated racks or is it simply placed on the floor?
Are the inventory levels controlled? Is the material easy to find or do operators have to look for it? Is well identified and easy to find? Is it clear who is responsible for replenishing line materials? Is 5S followed?
Production Line Storage
Production Line Storage
Production Line Storage
Production Line Storage
Production Line Storage
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
WIPWork-in-Process Inventory
Is WIP inventory well organized and controlled? Is WIP Inventory stored in designated locations? Is it clear who is responsible for that inventory? Is 5S in place? Are Min/Max levels controlled?
Work in Process Inventory
Work in Process Inventory
Work in Process Inventory
Work in Process Inventory
Work in Process Inventory
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Inventory Control
Is there inventory management system in place? Are the inventory levels well defined? Are the inventory rules easy to see and follow? Is there Visual Management in place for inventories?
Inventory Control
Inventory Control
Inventory Control
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Finished Goods Warehouse
Is there a central warehouse for all finished goods? Are all finished goods well organized? Are proper storage racks in place?
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Finished Goods Warehouse
Is the FG warehouse clean and well organized? Is it a Safe environment? Is it easy to locate products?
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Finished Goods Warehouse as a Supermarket
Is the FG warehouse designed as a Supermarket? Is material easy to find and locate? Are parts shortages easy to identify?
Finished Goods Warehouse
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Packaging of Finished Goods
Is there a designated Packaging Area? Is it well organized and controlled? Is material flow and information flow easy to understand and
follow?
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Is there a designated shipping area - no other materials activities?
Is shipping traffic controlled? Are responsibilities well defined? Is material flow clear and easy to understand?
ShippingArea
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Are materials pre-staged prior to shipping? Is there a staging area used to prepare load and find shortage
prior to shipping? Is the next load staged at a fixed time before shipping? Are shipping responsibilities clearly defined? Is a shipping schedule available and easy to see?
Shipping Pre-Staging
Pre-staging of Shipping Goods
Shipping Boards
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Shipping
Are all materials loaded directly onto delivery trucks? Do the process one shipment at a time? Is the shipping process easy to follow and understand?
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
All materials are verified prior to shipping There is a transaction for every shipment Shipping data is entered immediately into a system Information is verified
Shipping Management
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Materials Management – Areas of Responsibilities
Customer Orders Production Plans/Schedules Purchased Parts (Raw Material) Warehouse Material Deliveries Production Line Storage Work-in-Process (WIP) Inventory Storage Inventory Control Finished Goods Warehouse Shipping
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
Changing the World. One Transformation at a timeThis presentation is an intellectual property of W3 Group Canada Inc.
No parts of this document can be copied or reproducedwithout written permission from:
Marek PiatkowskiW3 Group Canada Inc.iPhone: 416-235-2631
Cell: 248-207-0416
[email protected]://twi-network.com
Materials Management Areas of Responsibilities
Thinking win, Win, WIN
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