I'm ready to learn...what are you looking for? Do you just want to know how tightly each of us controls traceability? I really haven't done any benchmarking outside our own divisions before, so please excuse my ignorance
Kool, I'm excited now. OK heres for starters....
We need to maintian traceability so if we have a problem with our customers we can track back and determine what product is nonconforming; preferably the least of the product.
Unfortunately we have many suppliers, and many different moves of product from one supplier to the next. This calls for several verifications of product when it gets back and several added on job numbers.
This has become cumbersome and time consuming and I'm looking for ways to simplify and still verify the processes.
Can you give me different ways you maintain this type of traceability through your systems?
A company I worked for about 15 years ago had a great system...I will try to describe it for you...
All material was received using a "receiving ticket/inspection report". These were sequentially numbered. After material was accepted, this became the lot number. If the material was "raw material", i.e. bar stock to be used in the machine shop, the lot number became the job number. If we had multiple uses for a particular "lot", we could break it down further by adding "-" numbers to the base lot number, i.e. Material from lot #1234 would be used for job #'s 1234-1, 1234-2 and so on. After all manufacturing of the componenet was complete, or if the part was purchased complete, the parts would be sent to the stock room until pulled for an assembly job. The router for the assembly listed a bill of materials and had a space to record the lot numbers for each item pulled for the assembly job.
This gave us full traceability back to the original mill or component supplier. And, unfortunately, it paid for itself when we had to do a product recall. We new exactly which customers had the defective product.
We also have a great system and can track back almost anything.
The only problem is it has become very cumbersome.
We give the incoming powder a lot number. We give every order a job number. The lot number remains on the paperwork through the process with the job number. The problems come in because we use many suppliers and parts of the same job number can be still in house, some of that job number can be at one supplier; and some can be at another supplier.
So these orders come strolling in a couple days at a time; and we do separate final inspections as they come in. This means in order to retain traceability; we need to add extensions on to all these original job numbers to keep them separate.
Do you think a job number such as 12-18-01/8874/J is too long?
believe it or not, most MRP systems have some lot control(traceability) built in, may be purchased as an extra module for some, but most have it in the basic package and just need to be activated and applied. So first... What are you using? What product/industry? What are the imposed/implied levels required? Are they subcontractors? Does the stuff come back inbetween? Is it sent in consigned kits or is it turnkkey? What are you doing now?
well all that was food for thought....
Benchmarking done correctly needs a base, similar to what Al started in his data base thread so you can compare apples to apples and to oranges with fruit salad as the goal.
So basically the plan I typically use is to find the players, and see/know the variables, then define what to benchmark and how to approach it(data to collect)....and then start the comparisons/gather the data. Some one reviews what is submitted and reports to the group.