Sharise Heenan has 16 years of experience in inventory, logistics, and materials management. She has a background in lean six sigma and is working towards her CPIM certification. She has strong materials management skills and experience with new product introductions and cost reduction projects. Some of her projects include reducing material move times by 40%, freeing up 90% of warehouse space for returns, and improving inventory accuracy.
Steps to set up a Medical device lean manufacturing facilityBlenson Paul
Steps to set up a Medical device lean manufacturing facility
Keywords:
Lean, Kaizen, Continuous improvement, 5S, KPI, DHR, NCR, QMS, ISO13485
Author : Blenson Paul
Steps to set up a Medical device lean manufacturing facilityBlenson Paul
Steps to set up a Medical device lean manufacturing facility
Keywords:
Lean, Kaizen, Continuous improvement, 5S, KPI, DHR, NCR, QMS, ISO13485
Author : Blenson Paul
In this presentation we are showing Highlights of Kaizen Lean Assessment Audit. For more information visit: https://in.kaizen.com/consulting/kaizen-lean-consulting.html
• Proficient in assessing physical layout of warehouse for storage of materials, spare parts & consumables and ensuring smooth accounting, issue of material to production & project sites.
• Skilled in streamlining system and procedures for effective warehouse management, inventory control & for monitoring flow of materials to and from warehouse with inventory module and generate reports in same.
• Expertise in implementing new warehouse operative shift pattern, managed training and multiskilling of staff to achieve greater flexibility across all functions.
• Resourceful in implementing new warehouse supervisory/management structure by creating clear job specifications
• Proven track record of directing and coordinating comprehensive logistical & reverse logistical functions for product life cycles, including acquisition, distribution, internal allocation, delivery, recycling, reuse and final disposal of resources
• Excellence in implementing inventory control measures to reduce obsolete stock, tracked slow-moving items and achieved reduction in inventory management cost.
• Successful in identifying and implementing warehouse efficiency plans resulting in a annual cost reduction.
• Proficiency in maintaining physical condition of warehouse by planning and implementing new design layouts; inspected equipment; issued work orders for repair and requisitions for replacement.
• A keen communicator with honed interpersonal, problem solving and analytical skills.
In this workshop, the participants will learn Lean tools and insights to remove waste in the warehouse leading to efficient, effective logistics & warehousing, reduced costs and improved service. Participants will then participate in a simulation exercise. The participants will experience the benefits of reduced costs and increased productivity.
In this presentation we are showing Highlights of Kaizen Lean Assessment Audit. For more information visit: https://in.kaizen.com/consulting/kaizen-lean-consulting.html
• Proficient in assessing physical layout of warehouse for storage of materials, spare parts & consumables and ensuring smooth accounting, issue of material to production & project sites.
• Skilled in streamlining system and procedures for effective warehouse management, inventory control & for monitoring flow of materials to and from warehouse with inventory module and generate reports in same.
• Expertise in implementing new warehouse operative shift pattern, managed training and multiskilling of staff to achieve greater flexibility across all functions.
• Resourceful in implementing new warehouse supervisory/management structure by creating clear job specifications
• Proven track record of directing and coordinating comprehensive logistical & reverse logistical functions for product life cycles, including acquisition, distribution, internal allocation, delivery, recycling, reuse and final disposal of resources
• Excellence in implementing inventory control measures to reduce obsolete stock, tracked slow-moving items and achieved reduction in inventory management cost.
• Successful in identifying and implementing warehouse efficiency plans resulting in a annual cost reduction.
• Proficiency in maintaining physical condition of warehouse by planning and implementing new design layouts; inspected equipment; issued work orders for repair and requisitions for replacement.
• A keen communicator with honed interpersonal, problem solving and analytical skills.
In this workshop, the participants will learn Lean tools and insights to remove waste in the warehouse leading to efficient, effective logistics & warehousing, reduced costs and improved service. Participants will then participate in a simulation exercise. The participants will experience the benefits of reduced costs and increased productivity.
During the module, we will run a lean improvement simulation. This simulation will involve your team running a ‘bad’ process alongside another team and through various iterations of improvement turning it into a ‘good’ process.
The team project report needs to analyse the decisions that you made during the simulation.
You should present some of the key data from the simulation – WIP, throughput time and improvement decisions. The report should then analyse what happened using process improvement and lean terminology.
In particular, the report should identify what happened (in terms of the decisions that you made) the impact of these decisions on the operation and then lastly make recommendations for what might be done differently next time (key learning points)
Please note:
• Limit your work to 8 pages
• The page count is all-inclusive and includes any graphs, tables, or references.
• As a formatting guideline use: Arial 12 point with 25mm margins on all four sides, A4 paper
• Cover pages, etc. are not required.
2. 16 years inventory/logistics/materials
management; 4 years production management
Lean and Six Sigma trained, started APICS
courses for CPIM certification
Strong materials management skills
New product introduction and cost reduction
experience.
Background
3. Experience
Functional
◦ Manufacturing Management
◦ Materials Management
◦ Logistics
◦ Purchasing
◦ Customer Service
Industry
◦ Optics and Optical Coatings
◦ Medical Coatings
◦ Medical Devices
◦ Industrial Products – Pumps & HVAC
◦ Chemical
◦ Aerospace
◦ Forgings
4. Project Management
Material Move Project
◦ Issue – Irregular pattern of truck receipts creating overtime
and delay in receipt of finished goods to warehouse
◦ Action – Created Material Move teams and process to
move finished goods from production to shipping
◦ Results – Reduced move time 40%
Return Material Lean Action Work Out (Lead)
◦ Issue – Large portion of one section of receiving
warehouse was utilized for return material that ended up
being scrapped due to shelf life
◦ Action – Determine process for plant to receive return
material and determine disposition
◦ Result – 90% of that warehouse section was freed for
incoming material. Reduction in scrapping of return
material
5. Project Management
Scrap Material Reduction
◦ Issue – Shipping warehouse had limited space for new
product; mixed pallets existed and out of date materials
was shipped to customer
◦ Action – Created process for product managers to review
and disposition shelf life material; worked with
management to increase scrap budget and to secure
resources to support project
◦ Results – Increased usable floor space 25%
NPI – Materials Management
◦ Issue – Visibility to parts status for new products was
limited
◦ Action – Developed process to determine status and to
create data for Management on status of project
◦ Result – Elimination of non-value added work and clear
understanding of parts status for projects
6. Project Management
Handling/Storage of Small Parts
◦ Issue – Small replacement parts were “lost” between
the floor and the receiving warehouse
◦ Action – Created receiving area for small parts and
revised stocking area. Established flow of material
through factory to warehouse, staffed area with
dedicated employees
◦ Results – Reduced lost components, improved
inventory accuracy and visibility to parts
Excess and Obsolete Inventory
◦ Issue – Visibility to Excess and Obsolete parts was
limited to finance and materials although other
departments were impacting the numbers
◦ Action – Created a review process and work
instructions with Senior Management team
involvement
◦ Result – 10% reduction in excess and obsolete
7. Project Management
Kitting Scheduling
◦ Issue – OTD of kitted parts in warehouse resulted in missed
customer orders
◦ Action – Revised kitting process with dedicated scheduler,
conducted time studies, created tool to schedule kits and
established flow lanes for kit components
◦ Results – Improved fill rates and kit OTD, reduced floor space,
improved accounting understanding of kit cost
Receiving Exception Database
◦ Issue – Limited to no visibility to issues causing receiving
exceptions
◦ Action – Created new database to capture data, developed work
instructions and metrics to help drive out non-value added tasks
to receiving parts
◦ Results – 80% reduction in average days to close. Working with
supplier to address paperwork, quantity issues
8. Other Projects
KPI and trending data creation - improved fill rate 10%,
inventory reduction 15%
Lean supermarket, Kanban, VMI, JIT and receiving
warehouse development – reduction in lost time looking
for parts and inventory accuracy
Cross training program – reduction in overtime hours
OTD (delinquency reduction) project – 10% increase in
on time delivery, 42% decrease in standard deviation
(ITT Ring of Quality awarded Silver)
Physical inventory for shipping and receiving
warehouse resulting in less than 1% variance
Implemented lean manufacturing on a production line
Created cleaning and testing process for a medical
clean room
9. Inventory Materials
Management
Cycle count process on shelf life material and location
clean up to drive towards FIFO
Shrinkage review to determine driving factors impacting
shrink and develop processes to address
Overall inventory review by weeks on hand and team
work with planners/buyers to address
Materials management for new parts/products
introductions
ECN inventory review to determine impact of ECN and
work with Engineering to disposition properly
BOM management to assure quantity and component
accuracy
New forecasting system implementation (in blueprinting
stage Q12015
Various IT projects to improve system capabilities;
reduce manual tasks and improve process flow
10. Management Roles
Standard work creation and training
KPI and trending data creation
Employee Engagement
◦ Monthly one on one meetings
◦ Department games
◦ Open communications
◦ Staff meetings
Coaching and Development
◦ Individual development plans
◦ Employee improvement plans
◦ Mentoring
11. Career Themes
Leadership (execution, relationships, strategic thinking and
influencing)
Process Improvement (proven track record)
Bottom Line Impact (KPI creation and tracking/driving
metrics)