Shneha Rajesh Patel Charter 24/11/2015

CHARTER TO DEVELOP A SOLUTION FOR A KITTING PROCESSChange management

Version Nature of change Changed by Date

BUSINESS CASE

Currently the kitting levels on the production line are low. All the materials are being held track side. Materials that are being kitted are either DTO (design to order) or selected low usage parts. This project will examine the potential to increase this significantly over a period of time. The engineering and manufacturing departments have separate BOM (Bill of materials). The engineering BOM deals in placing part numbers in correct groups. The manufacturing department then puts these groups into routings to correspond with the correct operation or workstation and this is what controls the kitting process. The BOM (Bill of material) needs to be accurate as this drives the routings that will define where the kits are required on the build line. BENEFITS

More effective use of space at trackside. Reduced line feed operations. Better control of stock Reduce the multiple locations for the same material at trackside

SCOPE

In Scope All material except for high volume low value parts will be considered. All standard price list options Build line and sub-assembly Pre and Post-test build DTO (design to order) Assess the accuracy of the BOM and routings of the material.

Out of scope

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Shneha Rajesh Patel Charter 24/11/2015

Hardware - high volume low cost items Serialised material

DELIVERABLES/ KEY REQUIREMENTS

Analyse the data to assess the work content in stores. Time studies may be required for the work content of the kitting process.

Routing the BOM to the correct station or operation. Assess the possible changes to SAP viewer. How to identify the part numbers in the kit. Identify the best kitting process for a good outcome. Propose the most efficient and effective solution.

Kit for week – station-day-operation-engine Test the proposed solution and see what the outcomes are. Based on these

outcomes, refine or carry on with the process. Documentation and training for employees in the stores and the build line. Phase implementation – Testing the kitting process in small phases

depending on whether it is to be kitted to an engine, per week, operation stations or per day.

ASSUMPTIONS, CONCERNS, RISKS, CONSTRAINTS

1. Assumptions Adequate space for kitting in stores and on the build line. Routings would have to be up to date and accurate for the kitting to be

delivered to the correct stations or operation when needed. BOM have to be up to date.

2. Concerns The team changing CAT part numbers to dashes after 3 digits on the SAP

viewer programme due to an update. The project needs to understand the implications when it comes to the

routings. Is the kitting process going to be taken on-board before or after the build

line is moved into the new facility? The kitting will be based on the published production schedule which

will limit the opportunity to change. The effective dates on engineering changes will affect the kitting and

limit the ability to change the build schedules.

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Shneha Rajesh Patel Charter 24/11/2015

3. Risks Other projects are running simultaneously with this project and are using

the same resources. There would be the issue of prioritisation. Changes of part numbers to include hyphens.

4. Constraints Other projects are running simultaneously with this project and are using

the same resources. There would be the issue of prioritisation.

ADVANTAGES OF KITTING

Higher stock accuracy, (97% and above current figure) The operator does not have to go looking for the material hence increasing

the productivity. E.g.o C9 engine was picked as a kit before where the parts were placed on a

kit trolley and wheeled to the operating station. Material delivered based on production schedule. This increases the

efficiency of the system. Kit per engine means there is no space and time delay.

DISADVANTAGES OF KITTING

Limitations for the production manager to change his mind at particular time in the day.

Possibility could increase kit pickers – Could increase more personnel to increase the kits. Over staffed. Reduce line feeding.

Time – is there enough time to do the kits? How long will it take to pick each kit and deliver it to the appropriate operating station? The stability of the schedule must be related to the amount of time taken to prepare the kit.

Space-trolley-quantity of kit

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