1. 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. 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. 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. 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. 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. 6
Spare Parts Management

7. 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. 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, SMI
SK600T, 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. 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. 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. 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. 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. 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