materials management - areas of responsibilities - tps model

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1 [email protected] Materials Management Areas of Responsibilitie s Thinking win, Win, WIN Materials Management Areas of Responsibilities Marek Piatkowski – November 2016 Thinking win, Win, WIN

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Page 2: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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

Page 3: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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Page 4: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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.

Page 5: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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

Page 6: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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

Page 8: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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

Page 11: Materials Management - Areas of Responsibilities - TPS Model

Production Planning Boards

Page 12: Materials Management - Areas of Responsibilities - TPS Model

Production Planning Boards

Page 13: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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

Page 14: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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?

Page 18: Materials Management - Areas of Responsibilities - TPS Model

Purchased Parts Warehouse

Page 19: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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

Page 21: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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Material Deliveries

Is there a structure to material deliveries? Are the procedures and guidelines? Is there a process in place?

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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

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Page 23: Materials Management - Areas of Responsibilities - TPS Model

Material Deliveries

Page 26: Materials Management - Areas of Responsibilities - TPS Model

Material Deliveries

Page 27: Materials Management - Areas of Responsibilities - TPS Model

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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

Page 28: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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?

Page 29: Materials Management - Areas of Responsibilities - TPS Model

Production Line Storage

Page 30: Materials Management - Areas of Responsibilities - TPS Model

Production Line Storage

Page 31: Materials Management - Areas of Responsibilities - TPS Model

Production Line Storage

Page 32: Materials Management - Areas of Responsibilities - TPS Model

Production Line Storage

Page 33: Materials Management - Areas of Responsibilities - TPS Model

Production Line Storage

Page 34: Materials Management - Areas of Responsibilities - TPS Model

[email protected]

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

Page 38: Materials Management - Areas of Responsibilities - TPS Model

Work in Process Inventory

Page 39: Materials Management - Areas of Responsibilities - TPS Model

Work in Process Inventory

Page 40: Materials Management - Areas of Responsibilities - TPS Model

Work in Process Inventory

Page 41: Materials Management - Areas of Responsibilities - TPS Model

[email protected]

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

Page 44: Materials Management - Areas of Responsibilities - TPS Model

Inventory Control

Page 45: Materials Management - Areas of Responsibilities - TPS Model

Inventory Control

Page 47: Materials Management - Areas of Responsibilities - TPS Model

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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

Page 55: Materials Management - Areas of Responsibilities - TPS Model

[email protected]

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

Page 59: Materials Management - Areas of Responsibilities - TPS Model

Shipping Boards

Page 62: Materials Management - Areas of Responsibilities - TPS Model

[email protected]

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

Page 63: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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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

Page 64: Materials Management - Areas of Responsibilities - TPS Model

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Materials Management Areas of Responsibilities

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