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1
Marek Piatkowski – FSP Consulting
Materials Materials Strategy Strategy –– Milk RunMilk Run
Implementation Implementation
ProcessProcess
Marek Piatkowski
December 2010
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Marek Piatkowski – FSP Consulting
2
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Marek Piatkowski – FSP Consulting
Villeron
5 minute meeting every shift with supervisor
Tugger route
and stops
Audit
results
Implementation
Plan
Issue board
(audit and
check list)
Project BoardProject Board
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Marek Piatkowski – FSP Consulting
Process Design PrinciplesProcess Design Principles
Process design and implementation represents
only 30% of your success
Ability to sustain, maintain and continuously
improve newly implemented processes represents
70% of your success.
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Marek Piatkowski – FSP Consulting
A good Milk Run process
is a process that it is
• simple to understand
• simple to operate
•and easy to audit
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Marek Piatkowski – FSP Consulting
Verify that a system works
Maintain and sustain the system
Measure the performance of a system
Support standardized work
Involve supervision and management
Provide a guideline for observation
Tool for training
Tool for improvement
Why do we need to Audit Milk Run deliveries?Why do we need to Audit Milk Run deliveries?
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Marek Piatkowski – FSP Consulting
What to AuditWhat to Audit
Any system must have standards of operation clearly defined
Standards shall be audited to verify (check) that the system is
running properly, that standards are followed
Audit process shall be designed and implemented right from
the beginning of a Tugger Route
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Marek Piatkowski – FSP Consulting
How to AuditHow to Audit
Audit is done with a questionnaire. Only possible answers are
Yes or No
Questions, answers and comments are listed on the audit
document for easy analysis and follow up
Results should be plotted to make it visual. List of non
conformities, % of non conformities, trend graph, etc.. can be
shown
Pareto of non conformities can be done to identifiy
opportunities for improvement
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Marek Piatkowski – FSP Consulting
Who should conduct AuditsWho should conduct Audits
The Owner (Supervisor) audits the system every day until
results are satisfactory - then moves to weekly or monthly
audits
Support team reviews audit results daily
Manager reviews results at daily walk about, or during regular
management meetings
Corrective actions should be implemented
when non conformities occur
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Marek Piatkowski – FSP Consulting
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Questionnaire
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Marek Piatkowski – FSP Consulting
Results
Cell audited:
Manifold 2, 3 plus op 1et 2
Shift : morning
Description non conformities :
1
2
3 schedule not followed
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TUGGER
Résult - audit of :
one dolly stayed in cell F8Q
30/04/02
one box on ground without card
few boxes without card in picking area
81%
19%
% non conform
% conform
Historic of audits
52%
81%
86%
80%
81%
86%
81%
0%
20%
40%
60%
80%
100%
w
4
9
w
5
1
w
0
9
w
1
1
w
1
3
w
1
5
w
1
8
w
2
0
w
2
2
w
2
4
week
% o
f c
on
fo
rm
itie
s
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Marek Piatkowski – FSP Consulting
Pareto
Audit tugger -- pareto of non conformities
0
1
2
3
4
5
6
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27
item number (see audit questionnaire)
freq
uen
cy o
f o
ccu
ren
ce
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Marek Piatkowski – FSP Consulting
Lean Transformation SolutionsLean Transformation Solutions
Marek PiatkowskiMarek Piatkowski
F.S.PF.S.P. Consulting Inc.. Consulting Inc.
VM: 416VM: 416--235235--26312631
Cell: 248Cell: 248--207207--04160416
Marek.Piatkowski@rogers.comMarek.Piatkowski@rogers.com
www.TWIwww.TWI--Network.comNetwork.com
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