Question on CAR about inventory method

CAR states, "sheet metal inventory not in MRP and does not match paper inventory list"
I am new to this sector of manufacturing, but I have other sector experience. I wasn't here for this audit, but have the CAR. From what was explained to me, the auditor was concerned that each individual sheet of metal was not tagged, only a PO for the entire stack or bin. He was concerned that sheets could have been removed, altering the inventory. Since each order is job specific, we do not stock any 'extra' inventory. How do others deal with this? Any help would be appreciated.
 

Jim Wynne

Leader
Admin
CAR states, "sheet metal inventory not in MRP and does not match paper inventory list"
I am new to this sector of manufacturing, but I have other sector experience. I wasn't here for this audit, but have the CAR. From what was explained to me, the auditor was concerned that each individual sheet of metal was not tagged, only a PO for the entire stack or bin. He was concerned that sheets could have been removed, altering the inventory. Since each order is job specific, we do not stock any 'extra' inventory. How do others deal with this? Any help would be appreciated.

What kind of auditor? What was cited as being violated?
 
F

funkj - 2008

My guess is that the auditor is telling you that they want both the paper copies and your electronic copies to match.

One very easy way to get away from this issue is to eliminate the paper copy and just use your electronic version. That would negate his complaint.

If you must have the paper copies then every time one "piece" is removed the papers and electronic would require updating.
 
B

Boscoeee

CAR states, "sheet metal inventory not in MRP and does not match paper inventory list"
I am new to this sector of manufacturing, but I have other sector experience. I wasn't here for this audit, but have the CAR. From what was explained to me, the auditor was concerned that each individual sheet of metal was not tagged, only a PO for the entire stack or bin. He was concerned that sheets could have been removed, altering the inventory. Since each order is job specific, we do not stock any 'extra' inventory. How do others deal with this? Any help would be appreciated.

Is the CAR as written accurate, do you have sheet metal material that is not in MRP is one issue? Physical inventory meeting paper inventory and or MRP system is another issue?

It is normal to expect some level of material identification in Physical Inventory!:D

In our system we order all material to jobs, however any drops or excess that we have are labeled and MTR and certificates attached and held in controlled materials inventory.
 
F

funkj - 2008

I current work in plastic but did work in metals. Unfortunately in both cases we ordered bulk material and hence did not have "counts" that went with the inventory to the floor.

We knew what came in and what was taken but there was nothing on the floor were the inventory was waiting to identify its weight.

Probably a difference in the businesses, but that is why we do not have a "sheet" on the floor.
 
My situation exactly. I am mainly from the plastics industry also, we labeled 'units' only, not individual pieces. Also correct is that there are two issues here I think, the discrepancy between paper and data, and individual pieces can 'disappear', affecting the record.
 
J

joshua_sx1

:rolleyes: hmm... let me clarify… I guess, the auditor is asking for you to have a corrective action to eliminate the recurrence of discrepancy between your actual inventories with your inventory record… (if I got it right)…

…anyway, you also mentioned that the auditor is concerned about the individual sheet metal that was not tagged… probably he is more concerned on the probability that this sheet metal will be used to other product (having the same part requirements)… and therefore will cause delay to the intended product...

…for the 1st case (1st paragraph), you need only to establish a more efficient and accurate inventory monitoring system… wherein, your actual inventories will always match your records – at any given time…

…for the 2nd case (2nd paragraph), well, for me there is no need for any CAR on that situation unless of course it gave you a problem such as delaying the other product because the sheet metal has been used to other… or in most cases, PAR should be raised instead… to prevent delay on completion of product because the sheet metal allocated for that product was used to other…

...whatever, I guess you can clarify this with your auditor... ;)
 
C

CliffK

CAR states, "sheet metal inventory not in MRP and does not match paper inventory list"
I am new to this sector of manufacturing, but I have other sector experience. I wasn't here for this audit, but have the CAR. From what was explained to me, the auditor was concerned that each individual sheet of metal was not tagged, only a PO for the entire stack or bin. He was concerned that sheets could have been removed, altering the inventory. Since each order is job specific, we do not stock any 'extra' inventory. How do others deal with this? Any help would be appreciated.

Sheet metal is a commodity.

Fab and assembly shops I've worked with do not tag individual metal sheets. It would be terrible waste of time.

What requirement was cited as the basis for this thing?

Tagging the individual pieces of sheet metal won't prevent people from removing them.
 
D

D.Scott

There is no required method of inventory management in ISO9001:2000. You define how you will manage your own inventory. We have similar products in one of our plants (skids of foam) which are job specific. The inventory pulls are maintained on the computer but the individual sheets are not tagged.

Lot control is a different issue but sheets pulled must maintain lot control.

Another thing you need to consider is "customer owned" materials. If your customer owns the material in inventory, you may have to meet customer specific requirements.

I would ask your auditor for clarification on the finding. Have him detail what specific requirement he feels isn't being met.

Dave
 
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