Nadine Stoltz 42 Tocpa Sa 13-16 May 2019

www.tocpractice.
com
42 TOCPA International Conference

13-16 May 2019, Johannesburg, South Africa
The Vedoc journey with TOC
Name Nadine Stoltz

Company Ferro South Africa
VEDOC Powder Coating
Country South Africa
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Presenter’s
Nadine Stoltz logo
Nadine Stoltz is the National Sales & Marketing Manager

for Ferro VEDOC. Nadine is a recipient of the Peter Gate
Akzo Nobel award for highest mark achieved in the
Powder coating manufacture and application
qualification while enrolled at the South Africa Paint
Manufacturers Association (SAPMA). She also
successfully completed courses in Basic paint Photo
technology and application.
Nadine completed her B.Com Business Communication
degree at the North West University Potchefstroom in
2004 followed by a Honours degree in Marketing,
focused on Business Management; marketing and
related support services from the University of South
Africa (UNISA).
At Ferro VEDOC, Nadine has been a key member in a National Sales and Marketing
number of developmental projects, including Manager
restructuring of the sales organisation and ERP nadines@ferrosa.co.za
integration and QMS/Process Mapping.
+27 83 321 5527
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www.tocpractice.com 42 TOCPA International Conference
Presenter’s
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What is powder coating

• Basically ‘solid paint’
• Thermosetting or thermoplastic
• Environmentally friendly
• Extremely efficient
The VEDOC powder coating business

• 8000 + colours on record
• 228 make to availability items
• 650 customers
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Powder coating manufacturing process
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Where we started
• Evaluated buffer once or twice a year
• Sales frustrated with long lead times
• Stock outs on Make to stock items
• Engineer believing in TOC
Consequences
• Broken promises – not meeting lead times
• Stock outs
• Stress
• Favouritism / Intimidation
• Prioritising
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VEDOC Powder coatings 2016 – 2017
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Production Improvements
• Tracking material through production – Bar code
scanner traceability
• Shorten setup time of machines
• Increase THROUGHPUT (TOC management)
• Capture of machine settings (History and setup)
• Labour reduction (10%)
• Improvement in recoveries (10%)
• Decrease rejects (20%)
• Mill PLC logic optimisation
• Product library and management logic
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Production Improvements – Extruder control panels
Old New
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Old New
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Old New
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Tracking material through production – traceability
Tracking
Raw WH Weigh off Mixing Lab Extruding Milling
Control and Measure + TOC Management
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Identifying the bottleneck

60
50
40
30
Year-11
20 Year-12
Year-13
10
Year-14
0 Year-15
STD Formulation - % No
Cards Received Samples Conducted Test Per Product Pass Ton's per Tint Ave Year-16
Additions
Year-11 13 31.4 35.1 2.5 1.125 Year-17
Year-12 14.1 38.7 30.6 2.7 0.889 Year-18
Year-13 16.3 40.0 33.2 2.5 0.845 Year-19
Year-14 17.9 42.9 36.9 2.4 0.768
Year-15 20.1 48.9 37.8 2.4 0.677
Year-16 23.6 53.2 44.7 2.3 0.639
Year-17 22.1 48.7 45.8 2.2 0.607
Year-18 24.0 50.0 48.9 2.1 0.534
Year-19 26.7 52.0 51.7 2.0 0.446
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Presenter’s
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Identifying the bottleneck
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VEDOC Powder coatings 2018 – 2019
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Dynamic Buffer Management

• Objective system
• Reduce stocks (capital employed)
• Reduce stock outs of standard items - MTS
• Control branch stocks
• Give the customer better service - MTO
• Structured sales driven production plan
• Everybody on the same page
• Flexibility in the plant
• Make everybody's life easier
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Production Planning
• Prioritise according to status of buffers (dynamic
management)
• Assess buffer size - increase/decrease buffer based on
sales:
Too often red – Increase buffer
Too often green – Decrease buffer
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Production Planning
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Managerial Reports
• Pareto charts
• Due date performance
• Shipping buffers
• MTS SKU’s
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Managerial Reports: Lead times
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Managerial Reports: make to stock availability
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Results Achieved
• Reduced finished goods by 22 %
• 98 % MTS Availability
• Reduce lead time by 60 %
• Build trust and reliability
• Reduced stress
What’s next?
• Raw material dynamic buffer management (automation)
• Dynamic stock management at customers
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Presenter’s
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Tracking material through production – traceability
Tracking
Raw WH Weigh off Mixing Lab Extruding Milling
Control and Measure + TOC Management
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Presenter’s
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Thank you.
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Nadine Stoltz 42 Tocpa Sa 13-16 May 2019

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www.tocpractice.

42 TOCPA International Conference

The Vedoc journey with TOC

Name Nadine Stoltz

Nadine Stoltz logo

Nadine Stoltz is the National Sales & Marketing Manager

What is powder coating

The VEDOC powder coating business

Powder coating manufacturing process

VEDOC Powder coatings 2016 – 2017

Production Improvements – Extruder control panels

Production Improvements – Extruder control panels

Production Improvements – Extruder control panels

Tracking material through production – traceability

Raw WH Weigh off Mixing Lab Extruding Milling

Control and Measure + TOC Management

Identifying the bottleneck

Identifying the bottleneck

VEDOC Powder coatings 2018 – 2019

Dynamic Buffer Management

Managerial Reports: Lead times

Managerial Reports: make to stock availability

Tracking material through production – traceability

Raw WH Weigh off Mixing Lab Extruding Milling

Control and Measure + TOC Management

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