Problem: Material brought back from jobsites is not easy to
find in the warehouse, and is not kept track of at all. Goal:
Create a system to manage the organization and tracking of the
material.
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SIPOC SuppliersInputsPROCESSOutputsCustomers Material
SuppliersInitial MaterialMaterial makesStored materialProject
Managers Finished JobsLeft-over Materialits way to the Project
Managers Warehouse Manager Material Organizationwarehouse Project
Managers
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Strengths: Dedicated warehouse manager. Intelligent and able
project managers. Technologically capable.
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Weaknesses: Communication barriers between warehouse and
office. Older project managers may have difficulty learning new
system.
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Opportunities: Increase speed of material delivery. Decrease
time spent searching warehouse for material. Decreased costs for
jobs.
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Threats: Lack of willingness to learn new system in the office.
Increased temporary workload for warehouse manager.
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Customer(s)CTQ KPOV(s) KPIV(s) Communication between project
managers and warehouse manager Material placed in organized manner,
and tracked in system Project Managers Easy system to find correct
material Organized material Communication between project managers
and warehouse manager Warehouse Manager Material placed in
organized manner, and tracked in system Easy system to find correct
material
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DescriptionDistance Clock Time Task Time Wait TimeObservations
Driver Delivers Excess Material30 Miles32 min.. Does the driver
have another immediate delivery?No32 min.0. If yes.... Dump
material in most convenient spot.... Return from Delivery.... If
no.... Set Material in semi-organized location50 ft.92 min1 hr..
Project manager looks for material in warehouse100 ft.112 min.20
min..Manager wandered Warehouse for a while Does he find the
material?Yes112 min.0. If no.... PM orders material from
supplier.... If yes.... PM leaves driver note5 ft.114 min2 min120
min. Driver delivers material15 miles254 min.20 min..Driver does
not notice note for a while
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Project Name:Warehouse Material Tracking Output Metric:Finding
Material Date/TimeMaterial TypeMaterial FoundComment
10/20/2014MixedSomeMore than half was found 10/21/2014Metal StudsNo
10/21/2014Finishing MaterialsYes 10/21/2014Metal StudsNo
10/23/2014Acoustical GridSomeLess than half was found
10/23/2014Finishing MaterialsNo 10/24/2014Metal StudsSomeMore than
half was found
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Data Points Time taken searching for material. Whether or not a
PM asked the Warehouse manger for help? Did the PM find all the
material they were looking for?
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According to the data: The communication between the Project
Managers and the Warehouse manager does not show a correlation
between how long or if the material is found. Whether or not the
material is found shows a correlation between how much time is
spent looking. If the material is not available, then the Project
Manager spends more time looking than if the material is found
right away.
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The KPIV that causes the most problems with the KPOV is the
lack of a system that keeps track of available material within the
warehouse. This is shown by the increased time spent looking for
material that is not available in the warehouse. If there was a
list available, then the Project Manager could easily look at the
list and determine if what he needs is in the warehouse or not
without wasting time looking for it.
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Solution Matrix KPOV(s):Material placed in an organized and
tracked. Solutions KPIVs: Excel File Visible to All Weekly Meetings
Full Time Material Manager KPIV #1Communication 486 KPIV #2Tracking
System 839 Success Criteria Total Impact 16129 Cost 1081 Likelihood
of Success 648
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Have warehouse manager make a list of material brought back or
taken away. Have office secretary input list into Excel file
visible to one project manager.
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Date: 12/1/201 4 Process: Control Process Step What's
Controlled? Input or Output? Spec. Limits / Requireme nts Measureme
nt Method Control Method Sample Size Frequency Who/What Measures
Review Frequency/ Corrective Action Make Material List ListInput
List all material ManualRun Chart100%Per Occurrence Warehouse
manager Weekly Friday 9:00 AM Input Material List Into Document
DocumentInput List All mateiral ManualRun Chart100%Per
OccurrenceSecretary Weekly Friday 9:00 AM Use document to search
material list Find Material Output 3 min. or less ManualRun
Chart100%Per Occurrence Project Manager Weekly Friday 9:00 AM
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Allowing other Project Managers to access the document Fill
them in on the process Total of 5 Project Managers
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Costs: Time of warehouse manager Time of secretary Benefits:
Saves money on material costs Saves Project managers time Helps
facilitate emergency material deliveries
