Work Instruction Logistics Insights Corporation Version 1.0 WI-30 LOC – Kitting August 23, 2003
This section briefly describes the process a Kitting Picker will go through on a ‘typical’ cycle for PPS. Equipment: 1. Tugger 2. Tophats (i.e. Hat Racks) on Quadsteers 3. Pick Lists and Delivery Sheets (As scheduled) 4. Clipboard 5. Ink Pen 6. Marker 7. Tape 8. Tophat Labels
General Guidelines: Always operate in a safe manner Maintain a safe and clean work area Use Personal Protective Equipment as required Adhere to scheduled lunch/ break times unless otherwise advised Always follow the specific path from Pick start to finish Picks must be completed within the scheduled time Ensure understanding of Contingency plan in case of system failure Process all Min violations and No Stocks Ensure accurate and timely Picks Communicate any performance issues to your Supervisor Understand and adhere to Customer requirements Ensure that material is at the required levels to maintain production by monitoring and recording MIN violations/ No Stocks If you see material dropping to critical levels without a response on MIN violation, notify your Supervisor or Material Analyst Any additional duties that need to be completed and/or may be requested by the Supervisor At the end of each shift park Tugger in designated parking area
LOC Route Kitting process: 1. Retrieve pick from PPS printer following pick schedule 2. Place printed Pick List and Delivery Sheets on clipboard 3. Proceed to designated kitting area located next to white route overflow 4. Verify part number on Pick List to AIAG label on container 5. Begin Pick of first part number on Pick List taking material out of standard pack and placing part in basket following visuals on kitting basket for placement of material 6. Continue until all parts are kitted (see Visual’s) 7. Verify quantity required for requested part number and distribute material equally into designated slots within kitting basket. 8. Fill pick order to pick requirements 9. Adhere to FIFO Process 10. Place a checkmark on the Pick List next to the part number once part is picked and placed in kitting basket (See attachment #2 )
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11.Review the MIN quantity on the rack label to determine if the Pick has created a MIN violation (number of containers in rack is less than MIN quantity on rack label). If MIN is identified, notify material analyst or supervisor immediately. 12. If there is no material in area for specified part request on the Pick List, cross off container quantity on Pick List and mark quantity short and N/S in comment field. 13.When all parts requested have been picked, Update Delivery Sheet with any changes from Pick List also note any shortages found by marking quantity short and N/S in the comment field 14.Tape Delivery Sheet onto Kitting basket 15.Stage completed pick in designated staging lane in front of C Dock Hat trailer for processing. 16.Notify hat drivers of completed kitting pick completion is now ready for departure. 17.Turn in pick sheets to material analyst.
Container Sorting and Restacking (See Special instructions below Attachment #1) Empty containers must always be restacked upside down with the exception of containers containing dunnage If UP Pallet is visibly damaged (Seatbelt/Buckle broken, not retracting to full extent) move damaged UP Pallet to Non-Conforming container staging lane. When pallet is full, top pallet off with lid, fasten seatbelts, and return to container stock return to designated CMC storage area Only stack containers to specified height/amount per Container Stacking Requirements (see attachment # 1 below) Proceed back to stocking until next scheduled Delivery Cycle Time
Attachment # 1
CONTAINER STACKING REQUIREMENTS CONTAINERS CONTAINER # HEIGHT PER SKID
SC/SD-241508 6 36
Contingency Plan (in event of system failure) If your Pick List and Delivery Sheet do not print, you must immediately notify your Supervisor for backup instructions If you are late in starting your Pick or fall behind in completing your Pick, please notify Supervisor once Pick is completed and notify Stocker for help in order to get back to schedule
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Attachment #2
No Stock=N/S Cross off # in containers field & write in # sent. Then in comments 3 sc field write in N/S & # sent
0 N/S-1 Check off part # field as part is picked
Engineering Change=ECS 157674676 ECS#NH924 Cross of old part # replace w/ new part # from ECS document. In comments field write ECS and the # on ECS document
53
BP
RG
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Total all Containers sent and write in # at Total containers shipped Write Initials in space Write Initials in space provided for Picker provided for auditor Work Instruction Logistics Insights Corporation Version 1.0 WI-30 LOC – Kitting August 23, 2003
Visual’s Distribute material equally across each parts designated holding slots.
Basket 1
15721234 15721233 15721232 15721231
15721231 15721232 15721233 15721234
Basket 2
Cross off shelf and write in new shelf. Place a SC in comments field 15760721
Basket 3
15009890 15009891
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Engineering Change If during the Pick process the DLOC and specified part number has an engineering change and the last container of the old part has been picked, the new part must be used in place of the old part (see Supervisor if this occurs) The old part number must be crossed off the Pick and Delivery List with the new part number written in The GM EWO (Engineering Work Orders) must be taped to the new part container (see attachment #4)
Attachment # 4 ENGR CHANGE
FLINT ASSEM.
SIGNATURES
CC: ECS COORDINATOR NICK NICHOLS ______RELIABILITY ______MATERIAL (FLOOR) ______PRODUCTION DEPT.L COOR. BODY ______CHASIS ______FINAL ______PAINT ______TRIM ______INSPECTION ______
REFER TO ECS#_____NH924______
PART(S) CANCELED DESC. PART(S) RELEASED EXH UE DISPOSE
______9442472______BOLT___ __11518446______X______
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