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How to ensure our employees donít grab and use the wrong materials - Page 2

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  Post Number #9  
Old 18th May 2018, 09:09 AM
RoxaneB's Avatar

Total Posts: 3,016
Re: How to ensure our employees donít grab and use the wrong materials

Some great ideas have been shared already and I'm probably going repeat (ummmm...summarize?) them here.
  1. Folks probably know what they should/shouldn't do. No one wakes up with the intention to deliberately mess up (I hope!). Explaining why it's important to use only the correct parts is important...explain the consequences/impact when they don't (loss of business, loss of customer, loss of job, loss of profit).
  2. I'll be facilitating some focus groups in the near future with staff who operationally "get" why things need to be done, yet we continue to lose money in this area. The idea is to have them drill down to why the errors are happening and have them come up with solutions. I'll then have them put the solutions on an effort/impact matrix before showing them which solutions fall into quick wins, major projects, fill-in-jobs, and thankless tasks. Quick wins will be our top priority to consider for implementation. Thankless tasks will need to be stopped. The remaining two will be looked at only once the quick wins are implemented.
  3. Segregate the components in such a way that the only ones they can access are the ones that should be used at that point in time. This presumes, however, you have a batch manufacturing process in place and blocks of product being made are either for that customer (or not for that customer).
  4. Visual management. Colours. Tags. Stickers. Paint. You could even go to the extreme measure of, if the part is large enough, tagging the ones that belong to you so that when they're used, the tag has to follow the product down the line and someone verifies that the part was used appropriately. No tag could imply that a customer part was used on the product when it shouldn't have been. Or, if it's the customer's product, the presence of a tag could mean that your part was used when it should not have been. Extra cost and rather "police mentality", but sometimes we need to go this route as a first step towards establishing a culture.
Thank You to RoxaneB for your informative Post and/or Attachment!

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  Post Number #10  
Old 18th May 2018, 01:16 PM

Total Posts: 166
Re: How to ensure our employees don’t grab and use the wrong materials

Can you put tape over the goods like this?

Message Marking and Warning Tapes - Safety Tapes and Applicators - Grainger Industrial Supply
  Post Number #11  
Old 18th May 2018, 04:29 PM

Total Posts: 3
Re: How to ensure our employees donít grab and use the wrong materials

Do you give materials your own item numbers? A purchased item and an identical customer supplied part could have different item numbers within your system to keep track of them easier.

Are inventory items issued to specific jobs?

Is there an inventory sign out sheet? Inventory moved on the back shifts can be documented and entered by the specialist the next day.

Are employees authorized to move inventory trained?

These processes help us a lot where I work and we no longer spend hours for that one box "I just saw last week".

Last edited by Pollyethelleen; 18th May 2018 at 04:31 PM. Reason: spelling
  Post Number #12  
Old 18th May 2018, 05:31 PM
Ninja's Avatar

Total Posts: 1,089
Re: How to ensure our employees donít grab and use the wrong materials

Pretty well covered already...

We had a request/fulfillment system...two different people.
If we had the same material bought and customer supplied, we called it different (similar) names in the inventory tracking system.
What job you took it out for was a required field...couldn't finish inventory withdrawal without filling it.

Bics Pens
Bic Pens from Xerox

When you looked down the list of dispenses, it was easy to see which dispense was not labeled "Xerox"...and easy to see whose account was logged in for that dispense...and who made the request.

Then we let folks know that using customer supplied material for our own products was, in fact, theft of customer product.
Never had another issue...for over a decade.

Thanks to Ninja for your informative Post and/or Attachment!

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