Transcript Date: 12/12/14 Team members: Nick Harrison • Problem: Material brought back from jobsites is not easy to find in the warehouse, and is not.

Date: 12/12/14
Team members: Nick Harrison
• 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.
SIPOC
Suppliers
Inputs
Material Suppliers
Initial Material
Finished Jobs
Warehouse
Manager
PROCESS
Material makes
Left-over Material its way to the
Material
Organization
warehouse
Outputs
Customers
Stored material
Project Managers
Project Managers
Project Managers
• Strengths:
• Dedicated warehouse manager.
• Intelligent and able project managers.
• Technologically capable.
• Weaknesses:
• Communication barriers between warehouse and office.
• Older project managers may have difficulty learning new system.
• Opportunities:
• Increase speed of material delivery.
• Decrease time spent searching warehouse for material.
• Decreased costs for jobs.
• Threats:
• Lack of willingness to learn new system in the office.
• Increased temporary workload for warehouse manager.
Customer(s) CTQ
KPOV(s)
KPIV(s)
Communication
between project
managers and
warehouse
manager
Material placed in
organized manner,
and tracked in
system
Easy system to find
correct material
Project Managers
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
PM's Order Same Material to
Two DIfferent Jobs, Causing
Delays.
PM Wastes Time Looking
for Material; Stops
Driver Delivers
Excess Material
Does the
Driver Have
Another
Immediate
No
Set Material in Semiorganized Spot in
Warehouse
Project Manager Looks
for Certain Material in
Warehouse
Does the
Manager Find
the Material He
is Looking For?
Leaves Note for Driver
to Deliver Material to
Certain Jobsite
yes
Yes
no
PM Doesn't See Material
That He Needs, but is
Actually There
Dump Material in Most
Convenient Spot and
Leave for Delivery
Return from Delivery
or
Material Never Gets
Organized
Project Manager
Orders More
Material from
Supplier
Driver Delivers
Material to Jobsite
Description
Clock
Distance Time
Task
Time
Wait
Time
Driver Delivers Excess Material
30 Miles
32 min.
32 min.
.
Does the driver have another immediate delivery?
No
32 min.
If yes
.
.
.
.
Dump material in most convenient spot
.
.
.
.
Return from Delivery
.
.
.
.
If no
.
.
.
.
Set Material in semi-organized location
50 ft.
92 min
1 hr.
.
Project manager looks for material in warehouse
100 ft.
112 min.
20 min.
.
Does he find the material?
Yes
112 min.
If no
.
.
.
.
PM orders material from supplier
.
.
.
.
If yes
.
.
.
.
PM leaves driver note
5 ft.
114 min
2 min
120 min.
Driver delivers material
15 miles
254 min.
20 min.
.
Observations
0.
Manager wandered Warehouse for a while
0.
Driver does not notice note for a while
Project Name:
Warehouse Material Tracking
Output Metric:
Finding Material
Date/Time
Material Type
Material Found
Comment
10/20/2014Mixed
Some
More than half was found
10/21/2014Metal Studs
No
10/21/2014Finishing Materials
Yes
10/21/2014Metal Studs
No
10/23/2014Acoustical Grid
Some
10/23/2014Finishing Materials
No
10/24/2014Metal Studs
Some
Less than half was found
More than half was found
Yard Storage
Warehouse Storage
Back Office
• 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?
METHODS
MANPOWER
MATERIALS
Bringing back material
Warehouse manager
Construction materials
Manager available
Organizing right away
Manager arrives to work on-time
Setting material in disorganized manner
Lots of material
Many different types of material
Material
Organization
Snow or Rain
Truck working properly
Time taken to find material
Very cold
Forklift working properly
MACHINE
ENVIRONMENT
Truck and forklift
Weather
MEASUREMENT
• 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.
• 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.
Solution Matrix
KPOV(s):
Material placed in an organized and tracked.
Solutions
Full Time
Material
Manager
Weekly
Excel File Visible to All Meetings
KPIVs:
KPIV #1
Communication
4
8
6
KPIV #2
Tracking System
8
3
9
Total Impact
16
12
9
Cost
10
8
1
6
4
8
Success Criteria
Likelihood of Success
• 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.
Date:
12/1/201
4
Process:
What's
Process Step
Controlled?
Control
Input or
Output?
Spec. Limits
/
Measureme Control
Requireme nt Method Method
nts
Sample
Size
Frequency
Who/What
Measures
Review
Frequency/
Corrective
Action
Make
List
Material List
Input
List all
material
Manual Run Chart
100%
Per Occurrence
Warehouse
manager
Weekly
Friday 9:00
AM
Input
Material List
Document
Into
Document
Input
List All
mateiral
Manual Run Chart
100%
Per Occurrence
Secretary
Weekly
Friday 9:00
AM
Use
document to Find
search
Material
material list
Output
3 min. or
less
Per Occurrence
Project
Manager
Weekly
Friday 9:00
AM
Manual Run Chart
100%
• Allowing other Project Managers to access the document
• Fill them in on the process
• Total of 5 Project Managers
• Costs:
• Time of warehouse manager
• Time of secretary
• Benefits:
• Saves money on material costs
• Saves Project managers time
• Helps facilitate emergency material deliveries