Brandy's Presentation ON TPM PARTS MARCH 2ND 2016
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Transcript of Brandy's Presentation ON TPM PARTS MARCH 2ND 2016
1
Spare Parts Management
• Organized & barcode labeled spare parts with sap information. Organized by machine used on! Bin color shows if stock or consumables in addition to labeling on each part & bin.
2
Spare Parts Management
This specific type & brand of labeler, the
Brother QL-570 or QL-700 Model #’s, are the
most cost effective way to barcode label bins
& parts. It is also thermal so no expensive
toner, either. Labels are 100ft long per roll,
which at 1” to 1.5” per label, makes each label
significantly less than a penny to purchase.
3
Spare Parts Management
• All purchase orders are received in by Shipping & then verified by me to have been received properly & that all part #’s & quantities match. Then parts are each labeled with the SAP part # pulled directly from SAP Purchase Order before putting away in correct location daily!!!
4
Spare Parts Management
• Frequent daily cycle counts are conducted to prevent parts from being used & not issued out without anyone knowing until it’s needed & too late, thus costing unnecessary down times.
• Counts are conducted blindly w/o any information on any of the parts from SAP. We use a notebook & write part # off of part, description & true location & then check for parts in SAP by searching the material master i have saved in excel – this method identifies duplicate part #’s & let’s me know which part #’s to block from future use in SAP to avoid having stock under multiple vendor #’s. I also like to reorganize as i do these counts & switch to blue bins & label each part with the correct SAP # & info.
• Weekend work parts staged for mechanics & labeled with SAP # to issue parts out under or as consumables. No guessing. Less Errors.
• Have gotten many recommended spare parts lists from vendors.
• Have gotten bill of materials from vendors to import into SAP.
• Building our machine history by purchasing almost all parts to stock & issuing them to the specific machine until used. These One time purchase stay on a special shelf & are labeled with part info when staged.
5
Spare Parts Management
• Have gotten blueprints for machines that are up-to-date with correct revision numbers on parts which speeds up the order process & parts request process considerably.
• Created one-time purchase & non-stock parts request form & as Rob Washer will tell you about shortly, he has created a database in access to track all requests & tie them to work orders & more.
• Organized consumables so it is easier to inventory & so we know when we are low on a product or part before we run out & the item is needed to repair a machine. This has caused unnecessary downtime in the past.
6
Spare Parts Management
7
Purchasing
• We are working as a team to set the safety stock on parts for each stock part at the time it is ordered thus eliminating excessive overhead in spare parts areas.
• Utilizing the “OTP” (One Time Purchase) shelf to track inventory only needed for special projects but not needing a safety stock. Results also in only purchasing what we need when we need it.
• Verifying all purchase orders are received in correctly & labeling all parts to match the SAP # purchased as or as consumables if purchased as consumables.
8
PM Planning
• I contacted OEM manufacturers or vendors who audit our machines & requested suggested preventative maintenance documents or planning paperwork. Also asked them for BOM’s to import into SAP & recommended spare parts lists. Also, asked for up-to-date manuals.
• OEM PM’s are now in SAP & have been scheduled to generate for the BL2 filler, Can Filler, Can Seamer, SMISK600T, Filtecs, R.A. Jones, Hi-cone, Krones, PAI & we have several other OEM recommended PM’s awaiting review to assure they fit our needs.
• After review we will add these OEM recommended PM’s into SAP & schedule them to generate too.
• I made binders for each machine to track progress & keep important hard copy documents – also on share drive so anyone has access if needed.
• Driving towards OEE, Overall Equipment Efficiency.
9
PM Planning
• We updated the structure in SAP to accurately reflect the machines we currently have & reported all Idle Eqt. to Corporate. Accurate structure enables us to pull reports like maintenance cost per machine for example from SAP, track parts usage & history in SAP & help to ensure we are completing time & cost efficient PM’s that add value & Only stocking necessary parts.
• Weekly reviews of PM’s are being conducted & changes made if a PM is not a value added type. Or if the OEM does not apply to us specifically, changes are also made. Additionally, we are adding PM’s specifically to meet our needs & address problem areas on our high-downtime machines first, then the rest of the machines will follow.
• Once a PM plan has been reviewed, we will immediately make the changes to the plan in SAP to ensure we are always doing the most cost efficient value-added PM’s. Machine PM plan’s will continue to be audited by a team yearly to make necessary changes! This is a continuous improvement process.
• Needed parts have been added to plans for PM’s needing them. This will cause the system to check stock for each part prior to PM & will call to order any needed parts by automatically creating a Purchase Req.
10
PM Planning
• Created functional & cost efficient oms-operational method sheet –stands out of schedule 80 pvc pipe & binder clips. These hold instructional sheets for every operator pm.
• Whole factory’s machines can be outfitted with individual OMS stands for less than $500 in materials VS. Storyboards which are costly & High Maintenance.
• Potentially can be used for SOP’s & Other Operator Communications since they are already checking this daily.
• SQF Compliant!
11
PM Planning
• The sheets are #’d with corresponding tasks on the form the operators fill out to show that they have completed the PM’s. See example here.
12
PM Planning
• Each task on the operator PM’s form (currently on Krones & Jones), have a place for feedback. We use this feedback to create a special kind of work order in SAP showing that the issue was discovered during a planned PM activity. This will allow us to see which PM’s that we have been planned are effective & value-added versus the less cost efficient PM’s that we may change to better suit our needs. Completed Operator PM’S are turned into me & reviewed Daily! I then confirm Work Orders daily & TECO at the end of each week.
13
PM Planning
• Operator PM’s in place are being done with the assistance of the OMS stands by great operators like Fonte Mixon – operators who take the time to do it right, give great feedback to prevent issues before they can lead to failures & who really do own it!!! With that, i hand it over to Fonte to tell you his side of things concerning operator PM’s here at Cott Sikeston.
» Thank you for listening! Have a lovely day! -BFOX