Todd Hester Service Center First Pass Fill Improvement - Cummins

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2 Service Center First Pass Fill Improvement Project: Improve the service center first pass fill percent from 79.2% to 83.2% while maintaining the Central Parts Warehouse fill rates at ‘Green’ level (≥86%) status. Belt: Todd Hester Sponsor: John Havel RDO / Distributor / Entity: Cummins Power South Net Annual Savings $256,660 * Savings based on reduced spend for engine down orders less the CPS freight recovery percent per month. Avoidance Savings: $0 Days to Close: 176 Project Closure Date: 9/23/2009 Project Closure Status: Green CFSS: No
3 Measure Phase – Highlights Service Center First Pass Fill Improvement Inputs (Xs) Outputs (Ys) Customer OE Demand Customer WO Demand Available Parts / Inventory BMS Suggested Order C/U/S C/U C/U C/U C Service Center Parts Order Fulfillment First Pass Fill Rate RECT Customer Satisfaction Back Order Quantities Xelus TSL Calculations C/U Inventory Turns CPW Parts Availability C/U Parts Usage History C Parts Allocated in BMS C WebCUMPAS Orders U Inputs (Xs) Process Outputs (Ys) Inbound Parts Bin Location C/U/S C C Parts Stock On Hand Inventory Allocation to WO / OE ticket Itemized Parts List C Received WO / OE Ticket C/U Itemized Parts Stock Replinishment C Work Order Demand C/U Customer Order Order Entry Demand C/U Work Order Quote C On Hand Inventory C/U Service Center First Pass Fill Improvement WO/OE/CUMPAS OE Customer Demand Customer Order C/U Backorder Item / Incomplete Order Allocate Order Filled Item / Complete Order Fill Pass Fill Rate Backorder Item / Incomplete Order C/U Satisfied Customer Filled Item / Complete Order C Invoice Customer Backorder Parts Unsatisfied Customer Part Sales History C Updated TSL's Support Stock C Xelus Usage levels Parts Stock Replinishment Recorded Parts Usage C Updated Branch Inventory Dollars Failure or Problem Service Center FPF 'Miss' Summary of Failure FTA (Fault Tree Analysis) SHEET Related Document Part Name Service Center First Pass Fill Abstract: This FTA investigates root Conclusion: Date Title Service Center First Pass Fill - Service (WO's) & Parts (OE's) causes of missed service center FPF parts. Development of Causes (Result - Cause) Action Plan Failure Mode (Top) WHY? Work Order FPF Miss Order Entry FPF Miss WHY? WHY? WHY? Xelus Suggested TSL Inaccurate Parts Not Available Mis-use Process Detailed Causes of (Top) Failure Mode Basic Characteristics Unpredicatable demand event MDC stock not avaiable Xelus has not yet established a TSL Parts Receipts Initiated in Process at Shop Order Qty > Max Stock Level Part In-Transit Quantity on Hand Available - Missed?? Open Order at Service Center Stock level depleted prior to next delivery Mobile (subloc) FPF process not followed Inconsistent use of support stock flags Lookup parts inventory or cost on WO or OE Inadequate Usage for Min. Stock Level Lack of Knowledge or Training on FPF Lack of Knowledge or Training on FPF Lack of Knowledge or Training on FPF Service Level Leadtime CPW Backorder Parts Usage Receipts in Process Xelus TSL Levels CPW Backorder to SC Miss Part Item History Order Received, not Allocated in BMS Sell Qty > TSL Parts Order / Ship but not at Branch Part on Hand at Branch, but not Filled Orders Open > 30 Days Low Qty/Ordered/Not Replinished in Time Mobile vs. In-Shop FPF Misses Standard Processes Exist Deleted Items from 'Live' OE / WO Same as Sell Qty > TSL result 80% of misses have an est. TSL = 0 Relationship exists with FPF & Mobile Inconsistent use, could incorp in training Relationship exists with FPF & Deletions Presumed Failure Mechanism No Problem Uncertain One of the causes X MEASURE ANALYZE IMPROVE • Process Maps • FTA • Failure Modes and Effects Analysis • Multi-Vari Studies • Design of Experiments (DOE) CONTROL • Control Plans TSL Transit Time QOH Available Open Orders TSL Training Training Training 15 12 7 3 3 Investigation Item Critical Input Variables Investigation Result Within 2 days, orders are not in process 4% of misses meet this criteria 1% of misses meet this criteria 2% of misses meet this criteria 4% of misses meet this criteria Judgemen t Found Critical X’s Controlling Critical X’s X X X X X X X All X’s 1st “Hit List” Screened List
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Page 7 and 8: 7 Analyze Phase - Highlights FPF 1.
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Todd Hester Service Center First Pass Fill Improvement - Cummins

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