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Marek Piatkowski – FSP Consulting

Materials Materials Strategy Strategy –– Milk RunMilk Run

Implementation Implementation

ProcessProcess

Marek Piatkowski

December 2010

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Marek Piatkowski – FSP Consulting

2

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Marek Piatkowski – FSP Consulting

Villeron

5 minute meeting every shift with supervisor

Tugger route

and stops

Audit

results

Implementation

Plan

Issue board

(audit and

check list)

Project BoardProject Board

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Marek Piatkowski – FSP Consulting

Process Design PrinciplesProcess Design Principles

Process design and implementation represents

only 30% of your success

Ability to sustain, maintain and continuously

improve newly implemented processes represents

70% of your success.

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Marek Piatkowski – FSP Consulting

A good Milk Run process

is a process that it is

• simple to understand

• simple to operate

•and easy to audit

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Marek Piatkowski – FSP Consulting

Verify that a system works

Maintain and sustain the system

Measure the performance of a system

Support standardized work

Involve supervision and management

Provide a guideline for observation

Tool for training

Tool for improvement

Why do we need to Audit Milk Run deliveries?Why do we need to Audit Milk Run deliveries?

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Marek Piatkowski – FSP Consulting

What to AuditWhat to Audit

Any system must have standards of operation clearly defined

Standards shall be audited to verify (check) that the system is

running properly, that standards are followed

Audit process shall be designed and implemented right from

the beginning of a Tugger Route

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Marek Piatkowski – FSP Consulting

How to AuditHow to Audit

Audit is done with a questionnaire. Only possible answers are

Yes or No

Questions, answers and comments are listed on the audit

document for easy analysis and follow up

Results should be plotted to make it visual. List of non

conformities, % of non conformities, trend graph, etc.. can be

shown

Pareto of non conformities can be done to identifiy

opportunities for improvement

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Marek Piatkowski – FSP Consulting

Who should conduct AuditsWho should conduct Audits

The Owner (Supervisor) audits the system every day until

results are satisfactory - then moves to weekly or monthly

audits

Support team reviews audit results daily

Manager reviews results at daily walk about, or during regular

management meetings

Corrective actions should be implemented

when non conformities occur

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Marek Piatkowski – FSP Consulting

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Questionnaire

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Marek Piatkowski – FSP Consulting

Results

Cell audited:

Manifold 2, 3 plus op 1et 2

Shift : morning

Description non conformities :

1

2

3 schedule not followed

4

TUGGER

Résult - audit of :

one dolly stayed in cell F8Q

30/04/02

one box on ground without card

few boxes without card in picking area

81%

19%

% non conform

% conform

Historic of audits

52%

81%

86%

80%

81%

86%

81%

0%

20%

40%

60%

80%

100%

w

4

9

w

5

1

w

0

9

w

1

1

w

1

3

w

1

5

w

1

8

w

2

0

w

2

2

w

2

4

week

% o

f c

on

fo

rm

itie

s

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Marek Piatkowski – FSP Consulting

Pareto

Audit tugger -- pareto of non conformities

0

1

2

3

4

5

6

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27

item number (see audit questionnaire)

freq

uen

cy o

f o

ccu

ren

ce

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Marek Piatkowski – FSP Consulting

Lean Transformation SolutionsLean Transformation Solutions

Marek PiatkowskiMarek Piatkowski

F.S.PF.S.P. Consulting Inc.. Consulting Inc.

VM: 416VM: 416--235235--26312631

Cell: 248Cell: 248--207207--04160416

Marek.Piatkowski@rogers.comMarek.Piatkowski@rogers.com

www.TWIwww.TWI--Network.comNetwork.com