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New Materials Organization Introduction
Thinking win, Win, WIN
Materials ManagementNew “Lean” Organizational Structure
Marek Piatkowski – November 2016
Thinking win, Win, WIN
New Materials Organization Introduction
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
New Materials Organization Introduction
Thinking win, Win, WIN
Materials Management Organization
Materials Manager
Operations Manager
Financial Manager
Plant Director
Three Legged Stool
New Materials Organization Introduction
Thinking win, Win, WIN
Materials Management Organization
Operations Manager
Financial Manager
Plant Director
PurchasingProduction Planning
Warehouse Management
LogisticsMaterial Handling
Materials Manager
New Materials Organization Introduction
Thinking win, Win, WIN
Materials Manager Materials Manager’s responsibilities
On-Time Customer deliveries Accurate and executable Production Schedule Supplier Development and Control Reduction and Inventory control Reduction of Lead Times Quick response to Customer needs Total elimination of line stops due parts shortage
Deliver to Manufacturing only: What is needed When it is needed and In the quantity that it is needed
New Materials Organization Introduction
Thinking win, Win, WIN
Materials Management Metrics - What to Measure
Site Measures Trend Goals
On time shipment up 100%
Inventory turns up TBD
Inventory levels down TBD
Inventory accuracy up 100%
Throughput to Sales up TBD
Forecast Error down 0%
Customer complaints down 0%
Schedule adherence up and leveled 100%
Leveled production up and steady +/- 5%
Production lot sizes down (single piece) Kit Size
Frequency of changeovers up EPED
Unscheduled changeovers down and eliminated 0%
New Materials Organization Introduction
Thinking win, Win, WIN
Production Planning
- Production Planner
- Inventory Analyst- Material Handling
Leader- Order Entry
- Material Handling Leader -
Material Handling Leader
PurchasingProduction Planning
Warehouse Management
Materials Manager
LogisticsMaterial Handling
New Materials Organization Introduction
Thinking win, Win, WIN
Production Planning Production Planner - Responsibilities
Master Planner Customer Orders Production lot sizes Production sequence and quantity Overtime schedule
Inventory Analyst - Responsibilities Maintenance of MRP system – lead times, order quantities, re-order
points, min/max levels, production lot sizes, delivery lot sizes, etc… Maintenance of BOM, “Shopping List/Pick List/Kit List” Management of new and obsolete parts and components Plan-for-Every-Part (PFEP) Introduction and maintenance of a Kanban system Inventory reporting and inventory policies (levels, controls and
management)
New
New Materials Organization Introduction
Thinking win, Win, WIN
Purchasing Department
- Buyers- Daily Orders- Supplier Management
PurchasingProduction Planning
Warehouse Management
Materials Manager
LogisticsMaterial Handling
- Production Planner
- Inventory Analyst- Material Handling
Leader- Order Entry
New Materials Organization Introduction
Thinking win, Win, WIN
Purchasing Department Traditional organization – no major changes Corporate Buyer
Purchasing guidelines and policies Inventory Strategy Supplier selection, evaluation, development and control Long term Supplier contracts, including Logistics Annual price, delivery and contract negotiations
Buyers Daily orders Daily deliveries External Logistics management Expedites if necessary
New Materials Organization Introduction
Thinking win, Win, WIN
Logistics – Material Handling
- Material Handling Leader- Shipping / Receiving- Internal material
deliveries- Line Feeders
PurchasingProduction Planning
Warehouse Management
Materials Manager
LogisticsMaterial Handling
- Buyers- Daily Orders- Supplier Management
- Material Handling Leader -
- Production Planner
- Inventory Analyst- Material Handling
Leader- Order Entry
New Materials Organization Introduction
Thinking win, Win, WIN
Logistics – Material Handling Material Handling Leader
Monitor and review schedule attainment Update Production Scheduling Boards Address any schedule issues or changes Address any parts shortage issues - troubleshooting Review and communicate any Production Plan issues and changes
with Line Management or Production Shift Supervisors Plan all sequential pulls and level loading Dispatch of forklift drivers, material handlers and Tuggers – all
internal deliveries Address any manpower or attendance issues/shortages within the
Material Handling organization
New
New Materials Organization Introduction
Thinking win, Win, WIN
Warehouse Management
- Materials Engineer -
- Warehouse Supervisors
- Materials Engineer
PurchasingProduction Planning
Warehouse Management
Materials Manager
LogisticsMaterial Handling
- Buyers- Daily Orders- Supplier Management
- Production Planner
- Inventory Analyst- Material Handling
Leader- Order Entry
- Material Handling Leader- Shipping / Receiving- Internal material
deliveries- Line Feeders
New Materials Organization Introduction
Thinking win, Win, WIN
Warehouse Management Supervisor Receiving & Shipping Warehouses - Responsibilities
Receiving process and data entry Warehouse policies and procedures Warehouse management and dispatching of materials for all deliveries
Materials Engineer - Responsibilities Overall Plant layout from the materials storage and delivery point of
view Design and layout of all material storage facilities, warehouses,
supermarkets, storage racks, point-of-use racks, parts presentation, etc …
Design of all material delivery equipment, material handling methods, delivery points, delivery routes and standards
Manpower planning for the Material Handling organization Development of standard containers and packs – supplier link Process and efficiencies improvements for Material Handling
organization
New
New Materials Organization Introduction
Thinking win, Win, WIN
Materials Management Organization
- Warehouse Supervisors
- Materials Engineer
PurchasingProduction Planning
Warehouse Management
Materials Manager
LogisticsMaterial Handling
- Buyers- Daily Orders- Supplier Management
- Production Planner
- Inventory Analyst- Material Handling
Leader- Order Entry
- Material Handling Leader- Shipping / Receiving- Internal material
deliveries- Line Feeders
New Materials Organization Introduction
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
New Materials Organization Introduction
Thinking win, Win, WIN
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