Understanding how to improve your parts production

1. Robert Counts
Counts Business Consulting, LLC

2. Who is Counts Business Consulting?
 www.countsbusinessconsulting.com
 Find us on Facebook
 Independent Family Business Consultants
 Onsite Consulting – Individual Yard Visits
 Owners’ Groups – Peer Groups Meet 2 to 3 Times a
Year
 Employee Training Materials & Seminars
 GoToMeeting - Managing, Sales, Buying, Family Business,
Excel
 CAR, Gold Seal, & URG Accreditation
 Website – Free Newsletter & Free Industry Articles
Counts Business Consulting, LLC

3. The 4 M’s
 Manpower
 Machine
 Material
 Measurement
Counts Business Consulting, LLC

4. Who are we talking about?
 Warehouse and beyond
○ Dismantling
○ Parts Gathering
○ Shipping/receiving
○ People who manage them
 All must use the Inventory Management
System
 All must work independently
 Outcome driven
 Answer 3 Questions
Counts Business Consulting, LLC

5. Order Tracker
Counts Business Consulting, LLC

6. How they Add Value?
 Understands that they are ultimately
responsible for the customers
experience
 Quality
○ Damage
○ Clean
 Timeliness
○ Prepared and ready to go when promised
Counts Business Consulting, LLC

7. IMS Specific Procedures
 Procedures need to be specific to the system
 Each Inventory Management System has
screen specific ways to complete a process
 I need to be able to train and manage with my
procedures
 Clearly states how much, how often and steps
needed to complete
Counts Business Consulting, LLC

8. Standardized Work
 Takt Time
 Cycle Time
 Crew Size
 Job Instruction Sheet
 Continuous Improvement
Counts Business Consulting, LLC

9. Killers of Performance
 Waste
 Over Inventory
 Over production
 Over staffed
 Transportation
 Excess Movement of vehicles
○ Drained place in yard
○ Part sold goes to dismantling
○ Cuts goes to dismantling
 Excess Handling of parts
Counts Business Consulting, LLC

10. Minimize Waste
 Eliminate Waste
1. Anything that does not add value to the
customer
2. Anything that does not add value to the
company – should be measured in
dollars
3. Any step or feature of a process than
can be improved
Counts Business Consulting, LLC

11. Minimize Movement
 Eliminate Handling
 Vehicles
 Parts
Counts Business Consulting, LLC

12. Manpower
 What skills
 How many
 How the position adds value to the
customer and to the company
 Must be trained and performance
observed
 There is no such thing as “one and done”
when it comes to training.
Counts Business Consulting, LLC

13. Movement
 Vehicles moved 3 times
 Vehicles stored sequentially
 Parts removed and stored according to
 Environment
 Sales
 Available storage
 Warehouse areas arranged so that high
volume high dollar parts closest to shipping
Counts Business Consulting, LLC

14. Machines
 From small tools to loaders
 From yard cars to fork lifts
 Computers and Printers
Make sure that those who need them have
them and they are kept in working order
Make sure that there is uniformity across
employees by position.
If the “machine” can eliminate or prevent
the addition of employee (s)
Counts Business Consulting, LLC

15. Materials
 What?
 Cleaning
 Packaging
 Core Bins
 Two way radio’s
 Information
 Where?
 Always in the same place
 Where the work is done
Counts Business Consulting, LLC

16. Measurement
 What gets monitored and measured
gets managed
 Better to Best – it’s a journey, not a
destination
 Available from the IMS
 Employee Accessible
 Sales
 Credits
 Number of
Counts Business Consulting, LLC

17. Measurements
 1.2 vehicles a day per BAY
 Inspect and gather 4 parts per hour
 Shipping and Delivery
 Prep, wash, package & load – 8 parts per
hour.
 Invoice all freight and delivered parts
 Produce the manifest
 Deliver
 Check in all returned parts
 Restock all returned parts
Counts Business Consulting, LLC

18. Order Tracker
Counts Business Consulting, LLC

19. Order Tracker Activity
Report
Counts Business Consulting, LLC

20. Managers?
 Operation/Production/Shipping Manager
 Trains new staff in:
 Standardized Work in Process
 Includes use of tools/equipment
 Inventory/Yard management system
 Spends up to 50% of their time training staff and
improving processes.
 Trains and rewards staff for incremental
improvements
 SWIP
 Customer Satisfaction
 Reduction in credits
Counts Business Consulting, LLC

21. Who is Counts Business Consulting?
 www.countsbusinessconsulting.com
 Find us on Facebook
 Independent Family Business Consultants
 Onsite Consulting – Individual Yard Visits
 Owners’ Groups – Peer Groups Meet 2 to 3 Times a
Year
 Employee Training Materials & Seminars
 GoToMeeting - Managing, Sales, Buying, Family Business,
Excel
 CAR, Gold Seal, & URG Accreditation
 Website – Free Newsletter & Free Industry Articles
Counts Business Consulting, LLC