1

Spare Parts Management

• Organized & barcode labeled spare parts with sap information. Organized by machine used on! Bin color shows if stock or consumables in addition to labeling on each part & bin.

2

Spare Parts Management

This specific type & brand of labeler, the

Brother QL-570 or QL-700 Model #’s, are the

most cost effective way to barcode label bins

& parts. It is also thermal so no expensive

toner, either. Labels are 100ft long per roll,

which at 1” to 1.5” per label, makes each label

significantly less than a penny to purchase.

3

Spare Parts Management

• All purchase orders are received in by Shipping & then verified by me to have been received properly & that all part #’s & quantities match. Then parts are each labeled with the SAP part # pulled directly from SAP Purchase Order before putting away in correct location daily!!!

4

Spare Parts Management

• Frequent daily cycle counts are conducted to prevent parts from being used & not issued out without anyone knowing until it’s needed & too late, thus costing unnecessary down times.

• Counts are conducted blindly w/o any information on any of the parts from SAP. We use a notebook & write part # off of part, description & true location & then check for parts in SAP by searching the material master i have saved in excel – this method identifies duplicate part #’s & let’s me know which part #’s to block from future use in SAP to avoid having stock under multiple vendor #’s. I also like to reorganize as i do these counts & switch to blue bins & label each part with the correct SAP # & info.

• Weekend work parts staged for mechanics & labeled with SAP # to issue parts out under or as consumables. No guessing. Less Errors.

• Have gotten many recommended spare parts lists from vendors.

• Have gotten bill of materials from vendors to import into SAP.

• Building our machine history by purchasing almost all parts to stock & issuing them to the specific machine until used. These One time purchase stay on a special shelf & are labeled with part info when staged.

5

Spare Parts Management

• Have gotten blueprints for machines that are up-to-date with correct revision numbers on parts which speeds up the order process & parts request process considerably.

• Created one-time purchase & non-stock parts request form & as Rob Washer will tell you about shortly, he has created a database in access to track all requests & tie them to work orders & more.

• Organized consumables so it is easier to inventory & so we know when we are low on a product or part before we run out & the item is needed to repair a machine. This has caused unnecessary downtime in the past.

6

Spare Parts Management

7

Purchasing

• We are working as a team to set the safety stock on parts for each stock part at the time it is ordered thus eliminating excessive overhead in spare parts areas.

• Utilizing the “OTP” (One Time Purchase) shelf to track inventory only needed for special projects but not needing a safety stock. Results also in only purchasing what we need when we need it.

• Verifying all purchase orders are received in correctly & labeling all parts to match the SAP # purchased as or as consumables if purchased as consumables.

8

PM Planning

• I contacted OEM manufacturers or vendors who audit our machines & requested suggested preventative maintenance documents or planning paperwork. Also asked them for BOM’s to import into SAP & recommended spare parts lists. Also, asked for up-to-date manuals.

• OEM PM’s are now in SAP & have been scheduled to generate for the BL2 filler, Can Filler, Can Seamer, SMISK600T, Filtecs, R.A. Jones, Hi-cone, Krones, PAI & we have several other OEM recommended PM’s awaiting review to assure they fit our needs.

• After review we will add these OEM recommended PM’s into SAP & schedule them to generate too.

• I made binders for each machine to track progress & keep important hard copy documents – also on share drive so anyone has access if needed.

• Driving towards OEE, Overall Equipment Efficiency.

9

PM Planning

• We updated the structure in SAP to accurately reflect the machines we currently have & reported all Idle Eqt. to Corporate. Accurate structure enables us to pull reports like maintenance cost per machine for example from SAP, track parts usage & history in SAP & help to ensure we are completing time & cost efficient PM’s that add value & Only stocking necessary parts.

• Weekly reviews of PM’s are being conducted & changes made if a PM is not a value added type. Or if the OEM does not apply to us specifically, changes are also made. Additionally, we are adding PM’s specifically to meet our needs & address problem areas on our high-downtime machines first, then the rest of the machines will follow.

• Once a PM plan has been reviewed, we will immediately make the changes to the plan in SAP to ensure we are always doing the most cost efficient value-added PM’s. Machine PM plan’s will continue to be audited by a team yearly to make necessary changes! This is a continuous improvement process.

• Needed parts have been added to plans for PM’s needing them. This will cause the system to check stock for each part prior to PM & will call to order any needed parts by automatically creating a Purchase Req.

10

PM Planning

• Created functional & cost efficient oms-operational method sheet –stands out of schedule 80 pvc pipe & binder clips. These hold instructional sheets for every operator pm.

• Whole factory’s machines can be outfitted with individual OMS stands for less than $500 in materials VS. Storyboards which are costly & High Maintenance.

• Potentially can be used for SOP’s & Other Operator Communications since they are already checking this daily.

• SQF Compliant!

11

PM Planning

• The sheets are #’d with corresponding tasks on the form the operators fill out to show that they have completed the PM’s. See example here.

12

PM Planning

• Each task on the operator PM’s form (currently on Krones & Jones), have a place for feedback. We use this feedback to create a special kind of work order in SAP showing that the issue was discovered during a planned PM activity. This will allow us to see which PM’s that we have been planned are effective & value-added versus the less cost efficient PM’s that we may change to better suit our needs. Completed Operator PM’S are turned into me & reviewed Daily! I then confirm Work Orders daily & TECO at the end of each week.

13

PM Planning

• Operator PM’s in place are being done with the assistance of the OMS stands by great operators like Fonte Mixon – operators who take the time to do it right, give great feedback to prevent issues before they can lead to failures & who really do own it!!! With that, i hand it over to Fonte to tell you his side of things concerning operator PM’s here at Cott Sikeston.

» Thank you for listening! Have a lovely day! -BFOX