2. Responsibilities
Ensure that the Shop floor had raw
material in order to keep a continuous
production flow
Manage the shop floor inventory
Give entry to the finished products of
3 different production lines
Glue sticks
Water based cleaners
Finger paints
Report and Register the payroll for 50
employees
Other Related Tasks to the shop floor
4. State of the department before my arrival
As you can see the department had a
great amount of raw material and boxes
laying across all the shop floor
5. After adopting SAP and appointing me to manage inventory (Sort)
I had to investigate around 150
different products in order to identify
the boxes laying on the shop floor
since most of them had no
identification or were overproduction
leftovers
To help with the identification
process, a tag was added that
included the SKU, the quantity and
the quality seal of approval in order
to return as much material as
possible to the warehouse for future
use
This process took around 2
weeks since i wasn't allowed to
stop the production line in order
to match the items with the
current system inventory
6. After all possible material was returned
to the warehouse, the leftovers were
classified on racks for easy
identification and also for assigning
specific places on the racks for each
independent production line
After the identification process
(straigthen-order)
Before
After
7. The result after a few more weeks of the
5’s program by making the workforce
aware of the problems that could be
avoided (Sweep-cleanliness)
9. I had to report the finished goods
that each line produced in order to
being either shipped or stored in
the warehouse
in order to do that i needed to work
with order production sheets that at
the same time were the place in
which the workers logged their own
work so the payroll could be made
that lead to the following problems:
Misplacement of the production
order
Over production and inaccurate
metrics needed for cost
calculation
Restocking on already stocked
orders
10. Based on a deep understanding
of the situation i proposed a
separation of this documents for
the following benefits
a better flow of information
between de shop floor and
SAP
a more controlled approach
on the activities of each
worker making the entry and
check of the payroll faster
Creating a visual system for
identifying process made to
the production orders making
them easier to read and sort
Production order
Workers log
