൨e end of this presentation please complete the required …1 0f 44 Hello and welcome to the Plex Physical Inventory video that was put together for our Paris and Muscle Shoals facilities

1 0f 44

PresenterPresentation NotesHello and welcome to the Plex Physical Inventory video that was put together for our Paris and Muscle Shoals facilities. At the end of this presentation please complete the required sign-in for course completion. If you have any questions, please contact your supervisor or team leader.

2 0f 44

PresenterPresentation NotesThis video will review the following topics. A quick reference pdf book of this presentation is also located on the site.

3 0f 44

Purpose of Physical InventoryNAL Benefit –

▫ Accuracy▫ Saves Money▫ Increased Customer Satisfaction▫ Increased Efficiency

NAL Requirement –• Requirement-1 time a year• Confirmation of NAL’s assets vs expenses and borrowings.• Audit reviewed asset evaluation

PresenterPresentation NotesNAL Benefit – Improve inventory accuracy in quantity and total dollar value. This will help ensure that each assembly line, molding machine, and process area have the correct components to build the needed FG lamps.NAL Requirement – By law we are required to be audited 1-time per year by an outside firm.The purpose is to confirm NAL’s assets vs expense and borrowings.If the outside auditors do not approve/agree with our asset evaluation NAL will be audited by the government and their timing/findings could impact our borrowing potential.

4 0f 44

Physical Inventory Preparation

Dec 1-Dec 23– Pre InventoryResponsibilities, Review and 6S

Areas▫ GF Responsibility▫ ME Manager and Program Management▫ Plant GM and/or Controller, PM Managers

▫ Plant Production Control Manager –Authorization is required forexcluded Items

Cleary marked "DO NOT INVENTORY" with an appropriate approval signature and current date.

Excluded items require approval

PresenterPresentation NotesDec 1-Dec 23 are the dates set for Pre InventoryI can’t stress enough about how important it is to review and 6's all areas accordingly. Each General Foreman is responsible for their area (Assembly, Process, etc.) for all production components, lamps, carts, packaging, etc.The ME Manager and Program Management are responsible for Any pre-launch components or FG lamps. It is important this is done and marked as a sample or with a “DO NOT INVENTORY TAG”The Plant General Managers and/or Controller should do multiple walk-through’s with GF’s, Mfg Emg and PM Managers at least 1-week before inventory begins.Specific authorization MUST be obtained from the Plant Production Control Manager to exclude items from inventory. These items must be clearly marked "DO NOT INVENTORY" with an appropriate approval signature and current date (Only the PC Manager, Plant GM , or Plant Controller). These items should be segregated from normal production material. Do not wait until the last minute to walk your area with the PC Mgr. Items to be excluded should be approved the week prior to start of inventory.

5 0f 44

Inventory Schedule When Inventory Task

2 weeks before inventory Service FG Builds Completed/Back to Service Pack

1 week before inventory Service Pack to Finish Packing All FG/Begin 6S.

1 week before inventory Service Pack Prep (Master Labels)

Last production day Minimized Production

Last production day Assembly Production Ends after 2nd Shift/3rd Shift-FG moves through audit to WH.

Day 1=12/29 Count Shared Source and Prep for Scanning

Day 2= 12/30 NO PRODUCTION and NO COMPONENT or FG MOVEMENT

Physical Inventory-100% Scanning

Day 3=12/31 Completed by Noon

Physical Inventory Recounts

After inventory Staged shipments

PresenterPresentation NotesThe inventory schedule is a great reference to use in knowing what is expected. This will be on page 5 of the pdf document located on the site.

6 0f 44

Physical Cycle Count Day1. Go to designated area2. Area Leader will review WIP Scan Process and Shared

Source Process

Important Note: DO NOT START SCANNING until your Area Leader gives you the ok (PC will need to make the location live) and the location you will scan. The location must be “live” for scanning to take. If scanning happens before the area is live, there will need to be a re-scan of every label.

Physical Inventory Instructions

PresenterPresentation NotesOn the day of the physical cycle count. go to your designated area. The Area Leader will go over the WIP scan process and Shared Source process, to ensure everyone understands their roll.

Please DO NOT START SCANNING until your Area Leader gives you the ok and the location as to which you are to scan.

If you start, before the inventory location is “live” in the Plex inventory application, it will not count and you will have to re-scan every label.

Only Production Control can turn on your inventory location.

7 0f 44

For Plex Inventory Manufacturing -Process and Assy Areas:

There are 2 ways in which the WIP components can be physically counted.

1. Scanning each Plex WIP label - Plex label and is specific to one Assembly line/lamp.

2. Entering “Shared Source” material onto a worksheet (Shared Source Cycle Count Sheet) – Small purchased components that are used across multiple lines.

Important Note: If you do not know if it is a Plex WIP Scanned Label or Shared Source, please ask your Area leader.


Shared Source Manual Ticket: Located on Container

PresenterPresentation NotesFor Plex Inventory Manufacturing -Process and Assy. Areas:There are 2 ways in which the WIP components can be physically counted.Click 1. Scanning each Plex WIP label - This will be for any item that has a Plex label and is specific to one Assembly line/lamp. Example: Housings, Lenses, Purchased Molded Components.Click 2. Entering “Shared Source” material onto the Shared Source Cycle Count Sheet – This is for small purchased components that are used across multiple lines. Example: Screws, Adjusters, and Clips. Click 3 refer to the picture: IMPORTANT NOTE: Shared Source items will NOT have a plex label. *Production Control manually enter those off the worksheetImportant Note: If you do not know if it is a Plex WIP Scanned Label or Shared Source, please ask your Area leader.

8 0f 44

For Plex Inventory Warehouse -Purchased Comp and FG:

1. All open boxes in the Warehouse need split for Assy SS and new Labels printed and attached to the container.

2. Scan all labels for purchased components and FG.

Important Note: Everything in the Warehouse should have a Plex label.


PresenterPresentation NotesNo Clicking

For Plex Inventory Warehouse -Purchased Comp and FG:

All labels for purchased components and FG’s will be scanned..

Everything in the Warehouse should have a Plex label. On day 1 of inventory, all open boxes in the warehouse need to be split from Assy SS and new labels printed and attached to the container to scan on inventory day.

*If you have a question about a component or FG, please ask your Area leader.

9 0f 44

For Plex WIP and WH Labels that will be scanned:What you should expect:1. WIP Locations Only=All mfg WIP Location that will be

counted in the plant.. 2. 6s Completed Properly▫ all work-center locations should be clear.

What to do if 6s isn’t completed properly, for example:• Your Team finds WIP parts on Assembly lines- Please

show your Area Leader, He/She will determine where the Plex WIP items should be scanned to.-If any of the items are approved to scan to the assy. work center, they will need to be “reloaded” once inventory is complete.

CAUTION: If they are not “reloaded” source will be depleted out of order and will cause production issues.


PresenterPresentation NotesClick 1-For Plex WIP and WH Labels that will be scanned:All Mfg. WIP locations, that will be counted in the Plant, should be WIP locations only. If 6’s is completed properly, all work-center locations should be clear. (Assy lines completely empty, process and mold machines completely empty)

Click 2-If Your Team finds WIP parts on Assembly lines- Please show your Area Leader, He/She will determine where the Plex WIP items should be scanned to.-If any of the items are approved to scan to the assy. work center, they will need to be “reloaded” once inventory is complete.Items that are approved to scan to the assy. work center will need to be “reloaded” once inventory is complete. Click3-If they are not “reloaded” source will be depleted out of order and will cause production issues.

10 0f 44

Process area WIP’s have designated locations. Example P1.125

1. Molding and Processing Work Centers-There should be 0 parts at these work centers.

2. Chemical rooms / Dryer Rooms-Have their own WIP locations, make sure their area team members available to assist with getting these areas counted 12/29/2020

3. Warehouse FG locations-Specific to part number.


PresenterPresentation Notes(No Clicking)Molding and Processing Work-centers have been cleared/empty and should not need to be scanned. (There should be 0 parts at these work centers)Chemical rooms / Dryer Rooms will have their own WIP locations – (make sure there are team members available to assist with getting these areas counted 12/29/2020Warehouse FG locations will all be specific to part number. Pay close attention to rack locations, finish good locations and lanes.

11 0f 44

Plex Label Scan Team: 1. 2 team members, 1-MH with scanner, 2-Verify each label2. Unopened box=Go by the label quantity.

3. Assy and Processing need to open all totes and verify qty.

IMPORTANT NOTE: If an auditor, supervisor, or area leader sees only 1 person scanning and no one to verify, that area will start over. If an auditor, supervisor, or area leader see the material handler scanning ahead of the team member verifying, stamping, and marking the team will be required to start over. SAFETYDo not climb on shelving, totes, racks, etc.


PresenterPresentation NotesClick 1-Each team WILL consist of 2 people. At least one person will need to be a material handler with a scanner. *One person will scan and one person will verify that each label was scanned and that the scanned quantity and label match. Click 2-If box is taped shut/original seal – Go by the label quantity.Click 3-If in a tote – Assy and Processing need to open all totes and verify qtyIf an auditor, supervisor, or area leader sees only 1 person scanning and no one to verify, that area will start over. If an auditor, supervisor, or area leader see the material handler scanning ahead of the team member verifying, stamping, and marking the team will be required to start over. This has happened the last 2 years. NO EXCEPTIONS.Please remember to work safely. Do not climb on shelving, totes, racks, etc.

12 0f 44

Assigned location:

1. Walk through: 1) 6’s is complete and 2) everything has a Plex label.

2. Notify area leader if you find a container or part that does not have a Plex label.

IMPORTANT NOTE: DO NOT START SCANNING until your area leader gives you the ok and verifies the location is “live”.

Detailed Scan Instructions

PresenterPresentation Noteseach team will go to their assigned location.

Click 1- Before you start scanning labels, 1st walk through the area and make sure 1) 6’s is complete and 2) everything has a Plex label.

Click 2 If you find a container or part that does not have a Plex label, please notify your area leader, team leader or supervisor. They will get you the needed label. Very important this happens prior to the start of scanning productPlease DO NOT START SCANNING until your area leader gives you the ok and verifies the location has been activated and the Physical Inventory application and is ready.

13 0f 44


“live” Area:Area Leaders give the ok-MH Team Member will do the following:

1- Login to the scanner2-select “Inventory” 3-select “Cycle inventory.”

PresenterPresentation Notesyou have been given the ok, from your supervisor, and have an active location or locations to scan, the material handler will sign on to the scanner with their sign on. Click 1-Select loginClick 2-Select InventoryClick 3-Select Cycle Inventory

14 0f 44

Detailed Scan Instruction Summary Sheet

PresenterPresentation NotesSummary Sheet For Scan Directions:Your Area Leader will have copies of this sheet. My hope is to also have this loaded to the site.

15 0f 44

Step 1:MH Team Member (MHTM)-Scan the location placard of the assigned area then will scan the first container in that area. *call out the quantity that the scanner shows for that label. Verify Team Member (VTM)- Verify the quantity.1. The verify team member will review to make sure qty on label

matches qty in the container. i. If not, VTM will correct the label qty with a purple pen. MH TM

will change qty. then hit “account for” on scanner. ii. If it matches, then the MH TM click’s “account for” in the

Scanner. The VTM will then Stamp, Initial, Date the label.


PresenterPresentation NotesStep 1:The material handler will scan the location placard of the area that they have been assigned and then will scan the first container in that area. When they scan the label, they are to call out the quantity that the scanner shows for that label. The other team member will then verify the quantity displayed on the scanner matches the qty in the container. The team member will then look to make sure qty on label matches qty in container. If not, they will write the correct quantity and correct the qty with apurple, on the label. If the quantity on the label matches the quantity on the scanner, then the material handler click’s “account for”. If the qty does not match what is on the scanner the material handler will change the qty then hit account for.

16 0f 44

QUANTITY and SCRAP CAUTION1. Some labels may show“0” on the scanner

i. The quantity will need corrected. If not, the quantity will update at “0”.

2. DO NOT SCAN “SCRAP” LABELS


PresenterPresentation NotesIT IS VERY IMPORTANT THAT YOU WATCH FOR THESE QUANTITIES AND CHANGE IF NECESSARY.

Click 1-You may come across some labels that show “0” on the scanner.

Please make sure you change the quantity to the correct quantity. If you do not, the quantity will update at 0.

Click 2-DO NOT SCAN “SCRAP” LABELS –

17 0f 44

For Process and Assy. WIP –MHTM- “account for “ scanner button, the VTM will stamp “scanned” in upper right hand corner (date, initials, and team #).Must beLegible.

For Warehouse FG and Service FG Labels -Be discreet: Mark in a NAL designated area, if missing, mark in a lower corner with marks small.


PresenterPresentation NotesClick 1-For Process and Assy. WIP – Once the material handler hits the “account for “ button, the other team member will stamp “scanned” in upper right hand corner of the label, showing that this label has been scanned. The date, team members initials, and team #assigned by dept supv will be written in the box.Make sure date and initials are Legible. Click 2-For Warehouse FG and Service FG Labels -Please be careful when marking on a customer label. We must be discreet. Please try to mark in a NAL designated area, if there is one. If not, please mark in a lower corner and make marks small.

18 0f 44

All Teams:Be consistent with scanned stamp

Why? 1-These labels will get “audited” 2-Process goes much quicker if the scanned stamps have a consistent location.

IMPORTANT NOTE: Internal Labels must have the “SCANNED” type stamp (placed in the same upper right hand corner location)


PresenterPresentation NotesClick 1-All Teams:Please be consistent with where you place your scanned stamp

These labels will get “audited” many times and that process goes much quicker if the scanned stamps are consistently in the same location.

Click 2-IMPORTANT NOTE: Internal Labels must have the “SCANNED” type stamp (placed in the same upper right hand corner location)

19 0f 44

Continue the scanning process…1. Watch closely for scanning error messages.

i. “container is inactive, do you want to update?” • click yes and enter the quantity for the label.

ii. “container has already been accounted for,” • verify the quantity again and change if

necessary. You can scan the label again if you are not sure.

REMINDER:DO NOT SCAN “SCRAP” LABELS


PresenterPresentation NotesNO CLICKINGContinue this process until all labels have been scanned and have a scanned stamp, in the designated spot, on each label.Watch closely for scanning error messages. The scanner may show “container is inactive, do you want to update?” click yes and make sure you enter the quantity for the label.The Scanner may show “container has already been accounted for,” this means it has already been scanned once, you will just need to verify the quantity again and change if necessary. If you are not sure if you scanned it or if you changed the quantity, you can scan the label again. DO NOT SCAN “SCRAP” LABELS

20 0f 44

Finish scanning the entire area1. Let Supervisor or Area Leader know your team is finished. Area leaders

will then print the cycle count results.2. The team will go out and try to located any unaccounted for inventory.3. Sheets will need to be returned to the area leader after the search is

complete. *Signed sheets by TL/Supervisor

Step 2: TL/Supervisor Check-100% of all container s will be checked for1. Labels2. All labels have a scanned stamp with date, team number and initials.TL/Supervisor Check-25% of all container s will be checked for1. Quantity and part number 2. They mark up with blue highlighter mark on the 25% of the labels, *For internal WIP labels, on the upper right hand corner. For Customer labels, in the designated area. Once complete report back to area leader.


PresenterPresentation NotesClick 1-Once you have finished scanning an entire area, please let your Supervisor or Area Leader know you are finished. Area leaders will then print the cycle count results and the team will go out and try to located the unaccounted for inventory. Sheets will need to be returned to the area leader after the search is complete. Sheets should signed by T/L and Supv after the search is complete

Click 2-Step 2:Your Supervisor or Team Leader will check that 100% of all containers have a label, and all labels have a scanned stamp with date, team number and initials. Click 3-They will verify quantity and part number on at least 25% of the labels. They will place a blue highlighter mark on the 25% of the labels, that they check. *For internal WIP labels, on the upper right hand corner. For Customer labels, in the designated area. Once complete report back to area leader.

21 0f 44

Detailed Scan InstructionsStep 3: GF Check 100% of all container s will be checked for1. Labels2. All labels have a scanned stamp with date, team number and initials.GF Check 5% of all container s will be checked for1. Quantity and part number (that do not have a blue mark). 2. They mark up with an orange highlighter mark only on the 5% Quantity and

Part number checks.* For internal WIP labels, on the upper right hand corner. For Customer labels, in the designated area.

PresenterPresentation NotesStep 3:Click 1-Next your GF will check that 100% of everything has a label and that all labels have a scanned stamp with date, team # and initials . Click 2-They will verify quantity and part number on at least 5% of labels (that do not have a blue mark). Click 3-They will place an orange highlighter mark only on the 5% that they check quantity and part number.

Click 4-* For internal WIP labels, on the upper right hand corner. For Customer labels, in the designated area.

22 0f 44

Finished GF Audit and Internal AuditStep 4:1. GF will contact the Area Leader. 2. Area Leader will notify control central of completion and the need of a

final internal auditor.Step 5:Internal Auditor-100% of all container s will be checked for1. Labels2. All labels have a scanned stamp with date, team number and initials.Internal Auditor-Check-25% of all containers will be checked for1. Verify quantity and part number (that do not have a blue or orange

mark)2. They mark up with a pink highlighter only on the 25% they audit.


PresenterPresentation NotesClick 1Step 4:Once the GF has finished his/her audit, they will contact Production Control area leader. PC will notify control central that area is complete and needs a final internal auditor.Click 2-Step 5:The assigned internal auditor will check that 100% of everything has a label and that all labels have a scanned stamp with date, team # and initials. Click 3-They will verify quantity and part number on at least 25% (that do not have a blue or orange mark). Click 4-They will place a pink highlighter mark only on the 25% that they audit. As shown here.�After this is complete, Report back to control Central that the Area is done

23 0f 44

Summary1. 100% of Labels have a scanned stamp with date, team #

and initials – Scan Team2. 25% of Labels have a blue mark – TL/Supervisor3. 5% of different Labels have an orange mark – GF4. 25% of different Labels have a pink mark. - Auditor


PresenterPresentation NotesClick 100% of Labels have a scanned stamp with date, team # and initials – Scan TeamClick 25% of Labels have a blue mark – TL/SupervisorClick 5% of different Labels have an orange mark – GFClick 25% of different Labels have a pink mark. - Auditor

24 0f 44

Error is found by the TL/Supervisor, GF or Internal Auditor 1. Notify the MHTM 2. The MHTM will re-scan with the correct quantity.3. Area will need to be cleared by the internal auditor.4. TL/Supervisor will report to the Area leader. 5. The Area leader will update the stats for the area and

will review to see that all areas are complete and that all items have been accounted for.

IMPORTANT NOTE: If items have been missed the Area leader will send the team out again to look for missing scans. DO NOT complete/close cycle counts.


PresenterPresentation NotesIf an error is found by the Supervisor, GF or Internal Auditor, they will Click 1 - notify the material handler and Click 2- -the material handler will re-scan the label with the correct quantity.

Click 3 - Once the area has been cleared by the internal auditor, Click 4 - the TL/supervisor will report to their area leader. Click 5- The Area leader will update the stats for that area and will review to see that all areas are complete and that all items have been accounted for.

If items have been missed the Area leader will send the team out again to look for missing scans. Note: DO NOT complete/close cycle counts.

25 0f 44

Detailed Scan InstructionsError is found by Team Members1. No Plex label2. No shared source ticket3. Incorrect part number - Fill out the quarantine tag and

move the parts with the tag to the quarantine area. IMPORTANT NOTE: Quarantine areas will be designatedwithin each plant. Area Leaders will communicate.

1. Ticket must be completely filled out. Part #, Qty, Return Location and Name. HOT!!!!

2. The quarantine Area Leader will log all tickets onto the master log.

PresenterPresentation NotesClick 1-Once you start scanning - If you find a container in your area that does not have a Plex label or a shared source ticket, or has an incorrect part number - Please fill out the quarantine tag provided and take the tag and the parts to the quarantine area.

Click 2- Quarantine area will be established within each plant . Your Area Leader will tell you where your area is located.Ticket must be completely filled out. Part #, Qty, Return Location and Name. HOT!!!! Last year this did not happen correctly.The Area Leader who is in charge of the quarantine area will log all tickets onto the master log.

26 0f 44

Summary of Import Things to Remember:

1. Verify quantity on scanner is correct before hitting the “account for “ button.

2. Make sure the correct location was scanned on the placard.3. 100% of everything gets scanned and stamped. 4. DO NOT SCAN “SCRAP” LABELS


PresenterPresentation NotesNo ClicksSo most important things to remember are….Make sure quantity on scanner is correct before you hit the “account for “ button. Make sure you have scanned the correct location placard for where your parts are located. Especially in the large WIP areas where the location changes with every row. And in the warehouse, where there are multiple rack locations. Make sure everything gets scanned and stamped.

DO NOT SCAN “SCRAP” LABELS

27 0f 44

Team Members Completed with Their Area1. Scanned all the labels 2. The area leader has been notified that you are doneThe Area Leader will then review results 1. If all correct, then the area is done.2. If large variances, your Team Members might be asked

to search for missing serial numbersAfter the area is done, the audits begin.

Remember1. Ask questions2. Take your time-accuracy is important3. Await GF approval before going home


PresenterPresentation NotesClick 1 Once the areas feel that they have scanned all the labels and the area leader has been notified that you are done (Click 2 )they will review results and if there is large variances you may be asked to go search for missing serial numbers that show in your area.

Click 3 If you have any questions or are not sure what to do, please ask.

Click 4 It is better to ask than to make a mistake……the consequence could be starting over on an entire area.

Click 5 Please take your time, there is no need to hurry. We have plenty of time today to make sure we do it correctly.

Click 6Your GF’s will give the approval for you to go home after they have communicated with the Production Control Manager to make sure they are not needed in another area.

28 0f 44

Detailed Shared Source InstructionsEntering “Shared Source” Material onto Shared Source Cycle Count Sheet

• Small purchased components that are used across multiple lines.

*PC will manually enter these components.

PresenterPresentation NotesNo clickingAgain - For Plex Inventory – There are 2 ways in which the WIP components can be physically counted.1. Scanning each Plex WIP label - Which we have reviewedor 2. Entering “Shared Source” material onto a worksheet – This is for small purchased component that are used across multiple lines. Ex. Screws, Adjusters, and Clips. Assy shared source will either be weigh counted or hand counted*Production Control will hand enter these components.

29 0f 44

Detailed Shared Source InstructionsStep 1: Shared Source Pre Counts1. Manual ticket filled out and attached to each container.

*Shared Source instructions will be provided the day of pre-count.

2. If multiple containers, the total needs to includeall containers and eachindividual container quantity listed separately.

IMPORTANT NOTE – EACH CONTAINER MUST BE HAND OR WEIGHT COUNTED.

DO NOT GUESS AT QTY IN CONTAINER

Alabama

Paris

PresenterPresentation NotesStep 1: Shared Source Pre Counts- A manual ticket should be filled out and attached to each container. *Shared Source instructions will be provided the day of pre-count.

If a ticket is filled out to represent multiple containers the total should represent all containers and each individual container quantity should be listed separately.

Click 2 IMPORTANT – EACH CONTAINER MUST BE HAND OR WEIGH COUNTED.DO NOT GUESS AT QTY IN CONTAINER

30 0f 44

Step 2: Transfer to a Shared Source Cycle Count Worksheet.

Provided to your area by PC

Detailed Shared Source Instructions

PresenterPresentation NotesNo ClickingStep 2: Once Shared Source counts are completed, for a designated area, counts are to be transferred to a Shared Source cycle count worksheet.That sheet will be provided, to your area, by Production Control.

31 0f 44

Transfer Data from the Pre-count ticket to the Shared Source sheet.1. Locate the correct part number2. Write the location and quantity for each shared source

on the count sheet.


Alabama

Paris

PresenterPresentation NotesNo ClickingOnce an area receives their Shared Source worksheet, from PC, a team of 2 will go to a designated approved area and transfer the data from the pre-count ticket, to the Shared Source sheet.

The team should locate the correct part number, on the sheet and write the location and quantity for each shared source count sheet. (very confusing the way this is worded.)

32 0f 44

Step 3: Pre-Count Ticket Stamp (after entry on Worksheet)1. An “Entered” stamp needs placed in the upper right

hand corner of the pre-count ticket. i. Place date, team number and initials on the ticket

IMPORTANT NOTE: This allows for the audit and ensures that another team does not copy down that same ticket.


Alabama Paris

PresenterPresentation NotesStep 3: After the shared source data has been transferred, to the Shared Sourced sheet, (Click 1 ) an Entered stamp will be placed in the upper right hand corner of the pre-count ticket. Place date, team number and initials on ticket

Click 2-This will allow for an audit and ensure that another team does not copy down that same ticket.

33 0f 44

Step 4: Returned Source Count Sheets to Area Leader

TL/Supervisor Check-100% 1. Pre-count tickets have an entered stamp 2. Includes date and initials, on the upper right hand side. TL/Supervisor Check-25% 1. Verify quantity, team # & part number 2. Place a blue mark on the pre-count ticket.


Alabama Paris

PresenterPresentation NotesStep 4: After all the shared source count sheets in your area, have been transferred to the Shared Source sheet, please return the sheets to your Area leader or Supervisor.

Click 1- Your supervisor’s or team leader will check 100% that all pre-count tickets have an entered stamp with date and initials, on the upper right hand side.

They will verify quantity, team # (Click 2) & part number on at least 25%. They will place a blue mark on the pre-count ticket.

34 0f 44

Step 5: TL/Supervisor Contacts PC 1. TL/Supervisor lets PC know they are done.2. PC contacts a final internal auditor.

Internal Auditor-100% 1. Everything has a ticket2. All tickets have: entered stamp (initial, team# and

date)Internal Auditor-25% 1. verify quantity and part number 2. They will place a pink mark on the label.


Paris

Alabama

PresenterPresentation NotesStep 5:Click 1-Once the Supervisor/TL has finished his/her audit, they will contact Production Control. PC will send down a final internal auditor.

Click 2-Your internal auditor will check 100% that everything has a ticket and that all tickets have a Entered stamp with initial, teamNumber and date

Click 3- They will verify quantity and part number on at least 25%. Click 4-They will place a pink mark on the label.

35 0f 44

Step 6:Shared Source worksheet to PC1. PC will manually enter into Plex. IMPORTANT NOTE:

Steps 5 and 6 MUST BE COMPLETE FIRST.

All Items counted as shared source must be on the shared source inventory list provided by Production Control.

For Questions: Contact your Area Leader or TL/Supervisor.


PresenterPresentation NotesNo ClickingStep 6:The internal auditors will then take the Shared Source worksheet to PC. PC will hand enter the data into Plex. Note make sure steps 5 and 6 are completed before sheets returned to PC. Last year this did not happen in all areas.

All Items counted as shared source must be on the shared source inventory list provided by Production Control.

If you have questions, please find your Area Leader or Supervisor.

36 0f 44

1. From the Scanner main menu, select the inventory option

Master Label Creation InstructionsMaterial Handler

2. Then select Build Master Unit

PresenterPresentation NotesThe Material Handler will create the master label.

Click 1 - On the main menu of your scanner, select the inventory option

Click 2 - Then select Build Master Unit

37 0f 44

3. Enter the location the product is physically located and click create. Master unit should be left blank

Master Label Creation Instructions

PresenterPresentation NotesNo Clicking3. Enter the location the product is physically located and click create. Master unit should be left blank

38 0f 44

4. Scan the serial numbers you are attaching to the master• Finished goods will all be 1 part number per master.

Receiving components can be mixed5. Ignore the add button6. Select the printer closest to your area7. When all serial numbers for the part number are

scanned, click the print button

Master Label Creation Instructions

PresenterPresentation NotesClick 1 -Scan the serial numbers you are attaching to the masterFinished goods will all be 1 part number per master. Receiving components can be mixedClick 2-Ignore the add buttonClick 3-Select the printer closest to your areaClick 4 - When all serial numbers for the part number are scanned, click the print button

39 0f 44

Master Label Creation Instructions8. For inventory, write the master number on a scrap

blank label and put it on the front of the lane or unit you are scanning

9. The part number will print at the top if there is only 1 part number associated with the master unit• NAL Master Unit will print across the bottom• The quantity for the master unit is in

containers/serial numbers

PresenterPresentation NotesClick 1- For inventory, write the master number on a scrap blank label and put it on the front of the lane or unit you are scanning (would be nice to have a picture)Click 2- The part number will print at the top if there is only 1 part number associated with the master unitClick 3-NAL Master Unit will print across the bottomClick 4-The quantity for the master unit is in containers/serial numbers

40 0f 44

Master Label Reminders1. Master labels at a manageable number2. Helpful tip-Print out a sheet from the inventory screen

of the master label and all the serial numbers within the master to help determine if all the serial numbers for the master are present prior to counting!• If a discrepancy is found on day 2 of inventory with

the master, all serial numbers need to be scanned individually and break the master

PresenterPresentation NotesClick 1- Keep your master labels to a manageable numberExample: 1 master label to row of housing, 1 master label per shelf in the racksClick 2- It can be helpful to print out a sheet from the inventory screen of the master label and all the serial numbers within the master to help determine if all the serial numbers for the master are present prior to countingIf a discrepancy is found on day 2 of inventory with the master, all serial numbers need to be scanned individually and break the master

41 0f 44

NOTE: SCANNED AND ENTERED STAMPS WILL BE NUMBERED AND SIGNED OUT OF PRODUCTION CONTROL BY THE AREA SUPERVISOR. ALL STAMPS MUST BE RETURNED AND SIGNED BACK IN PRIOR TO LEAVING 12/30. THE STAMPS CAN BE OBTAINED FROM THE PRODUCTION CONTROL MANAGER.

Distribution of Stamps

PresenterPresentation NotesNo clickingSCANNED AND ENTERED STAMPS WILL BE NUMBERED AND SIGNED OUT OF PRODUCTION CONTROL BY THE AREA SUPERVISOR. ALL STAMPS MUST BE RETURNED AND SIGNED BACK IN PRIOR TO LEAVING 12/30. THE STAMPS CAN BE OBTAINED FROM THE PRODUCTION CONTROL MANAGER.

42 0f 44

Quick review of what we covered:WIP and FG to be scanned1. Review the area for 6s2. Area Leader to signify “live”3. Always work in teams of 2. 1-MHTM 2-VTM4. Your TL/Supervisor will 100% check of your team’s area labels have a stamp, date, team # and initials

and they will audit 25% check of all containers for correct quantity. Blue Mark=checked5. Your GF will 100% check of your team’s area labels have a stamp, date, team # and initials and they

will audit 5% check of all containers for correct quantity. Orange Mark=checked6. Your Internal Auditor will 100% check of your team’s area labels have a stamp, date, team # and

initials and they will audit 25% check of all containers for correct quantity. Pink Mark=checked

Shared Source Parts1. Review the area for 6s2. Get the Shared Source worksheet from PC. 3. Always work in teams of 2. 1-enters the shared source data 2- verifies the data was transferred

correctly, and stamps the ticket with “entered” and place date, team # and initials on the ticket

Before Leaving1. Verify all supplies were returned to PC2. Ensure all scales returned to the warehouse3. Verify quarantine area product was retrieved and scanned to the location it originally

came from

PresenterPresentation NotesClick 1- For WIP and FG parts that will be scanned – 1st Make sure your area is 6’s, all containers and FG’s have labels and your area is ready to inventory.2nd Get the ok from your Area Leader that the designated area has been moved to “live” in the Plex system, and you are ready to scan.3rd Always work in teams of 2. 1 person will scan and call out the quantity and the other person will verify the label was scanned, the correct quantity was entered, and place a scanned stamp with date and initial on the label.4th Your Supervisor or Team leader will check that 100% of your area labels have a stamp, date, team # and initials and they will audit 25% of all containers for correct quantity. They will place a blue mark in the upper right hand corner for internal WIP and in designated area for FG’s.5th Your GF will check that 100% of your area labels have a stamp, date, team # and initial and they will audit 5% of all containers for correct quantity. They will place an orange mark in the upper right hand corner for internal WIP and in designated area for FG’s.6th An Internal Auditor will check that 100% of your area labels have a stamp, date, team # and initial and they will audit 25% of all containers for correct quantity. They will place a pink mark in the upper right hand for internal WIP and in designated area for FG’s.Click 2 Shared Source Parts1st make sure your area is 6’s, all containers have a shared source count and your area is ready to inventory.2nd Get the Shared Source worksheet from PC. 3rd Always work in teams of 2. 1 person will enter the shared source data onto the worksheet and the other person will verify the data was transferred correctly, and stamp the ticket with entered and place date, team # and initials on the ticketClick 3- Before LeavingVerify all supplies were returned to PCEnsure all scales returned to the warehouseVerify quarantine area product was retrieved and scanned to the location it originally came from

43 0f 44

Happy Counting/Scanning.

Please remember safety 1st.

PresenterPresentation NotesThis concludes our session. Please remember to use your smart phone to scan the QR code for course sign in.

If you have any audit question, your team leader or supervisor can assist you Happy Counting/Scanning.

Please remember safety 1st.

44 0f 44

Scan the QR Code for Course Completion Credit using your SMART Phone

Sign-In QR Code

Course Title:Plex Physical Inventory

PresenterPresentation NotesShow the class how to get to the survey in Plex. Each trainer should have a link that will get them to their results.

Plex Location:1-Plex PCN Location2-DCS3-Training4-Forms

Plex Physical InventoryTopics ReviewedPurpose of Physical InventorySlide Number 4Slide Number 5Slide Number 6Slide Number 7Slide Number 8Slide Number 9Slide Number 10Slide Number 11Slide Number 12Slide Number 13Slide Number 14Slide Number 15Slide Number 16Slide Number 17Slide Number 18Slide Number 19Slide Number 20Slide Number 21Slide Number 22Slide Number 23Slide Number 24Slide Number 25Slide Number 26Slide Number 27Slide Number 28Slide Number 29Slide Number 30Slide Number 31Slide Number 32Slide Number 33Slide Number 34Slide Number 35Slide Number 36Slide Number 37Slide Number 38Slide Number 39Slide Number 40Slide Number 41Slide Number 42Questions/Comments: �Team Leader or SupervisorSlide Number 44

Documents

൨e end of this presentation please complete the required …1 0f 44 Hello and welcome to the Plex Physical Inventory video that was put together for our Paris and Muscle Shoals facilities