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