Flatstock Flatstock Sorting/StockingSorting/Stocking

Berryville PlantBerryville Plant2/22/082/22/08

Team Members

Ron SiegristJoan HicksCarolyn ArmelLinda KeelerPaul MarquardtTerri AllenDaniel AtkinsLynne BurdenMilton TylerKristie Ostrander

Goals

• Reduce stocking times of flatstock material• Develop a stocking location for each part • Establish 5S system w/metrics• Develop a stocking system that promotes “first in /

first out”• Implement Kanban signals to trigger flatstock orders• To improve safety and provide a safe working

environment for all employees• Promote stronger communication among all

employees• Improve layout for kitters / stockers / cycle counters

Issues

• All parts stocked by hand in flatstock aisles• Incoming material palletized inconsistently• Location and rack order of components• Delivery area overly crowded and cluttered• Racking is not fully utilized• Excessive transit• Excessive walking• Inventories need adjusted• No 5S system for maintaining order

Flatstock Process Flow 2/18/08

Layout Before

With the removal of In Stock cabinets, many flatstock areas have not been fully utilized.

Team Work!!!!

Implemented Ideas

• Improve Visual Management• Develop labels for flatstock components• Implement First In / First Out signals• Determine correct pick locations by volume• Established 5S system• Vanity backs stored with vanity bottoms• Toe kicks and base spacers in one rack• Moved PW and PB shelves together• Lowered pick locations• Ability to stock from the back in some

locations. More room in kitting aisle• Created overstock location

Implemented Ideas

Improved Visual

Management

Accurate Part Labels

Implemented Ideas

Implement First In / First Out in stock areas. Pick from green. Stock in red.

Implement First In / First Out in stock areas. Do not

pick rows with red parts

After Layout

Adjusted pick locations to correct inventory levels

Results

Goal Before After Improvement %

Kitting cycle time990 seconds per

cart870 seconds

per cart 12%Square footage 11,700 sq ft 9,800 sq ft 17%Visuals 6 10 67%5S score .95 3.8 400%Label and ID Component Parts ???? 120

              

30 day list

Opportunity Owner Due DateComplete labeling and pallet locations for over stock Roger Leach 3/5/08

Create and distribute flat stock usage list to stockers David Schaffer 2/29/08Complete labeling and “first in first out” system for entire flatstock area Wayne Dodson 3/14/08

Paint trash bin Larry Edmonson 2/29/08

Complete VisualsRoger Leach

3/7/08

Future Opportunities ID’d

• Investigate high usage items palletized on one skid.

• Complete relocation of materials in the entire flatstock area.

• Implement findings in return area.• Flatstock items to be cut in mill.• Review flatstock items to be used for UT’s,

Misc Cell, and Mill Parts.

QUESTIONS?????