Material Handling - Accessories
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Transcript of Material Handling - Accessories
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Proposed Solution
eKanban Material Supply
27-Feb-2014
by IT Department
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ObjectivesReduce line-side accessoriesDeliver accessories to shop-floor at the needed time (Neat just-in-time)Automate material pull systemeKanban (Terminate issue slip process)MRP accuracy (Result as less shortage and less over supply)
Product costing accuracy
eKANBAN Material Supply
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Process/Function As-Is eKanbanHow to request accessories? 1.Determine requirement
2.Create&print reservation3.Submit reservation
Automate trigger signals from
yield confirmation to delivermaterial
When to call for accessories? In advance for few days Once WIP sitting at the Finishingwork center
Who takes care of delivery?
Deliver to shop-floor by production
Deliver to shop-floor by store
Store service time 8:00-17:00 24 hrsWhen to post goods issue? As-Is Few minutes after deliveryNumber of line-side accessories Huge number of accessories sitting Less, by depend on number of WIP
exist in Finishing work centerYield Confirmation(Scan Barcode) Collect job-ticket to scan in batch 2-3times a day Yield at trigger point must beconfirm as soon as possible
(May change to confirm by workerin the near future)
Unplanned Requirement In doubt Must follow work instructionMRP Not possible No doubtCharge cost of accessories to Cost center or Production order Production order
As-Is and eKanban ComparisoneKANBAN Material Supply
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Scope of ImplementationMaterial Group Time Frame NoteAll material groups of Fin
supply by Fin-store andMain-Store
Trial Run SM1004 - SM FIN WL High-EndSM1005 - SM Dragger boards
SM1006 - SM Nose Protector
SM1013 - SM Fin G10
SM1014 - SM Fin Wet Lay up
SM1015 - SM Fin Prepreg
SMXXXX - RTM FinSM1018 - SM Accessory Fin
Pad Next PhaseSticker Next PhaseFoot strap Next PhaseEPS Next Phase Triggered signal from released of production
order
eKANBAN Material Supply
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Trigger Point and Part requirement pointTrigger Point Assembly/Part usage pointTrimming PaintingPainting FinishingRelease of production order Press
Issuing Storage LocationMaterial Group Procurement Type Storage locationAll groups of Fin In-house Production PM10Fin StoreAll groups of Fin External Procurement 1100Main StorePAD01 1100Main Store
Note: Storage location in eKanban can be changed by requester or by store
eKANBAN Material Supply
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Parts List
(BOM)
Store
Press
Sanding
Laminate
Trimming
Painting
Finishing
Packing
PartsSupplier
Painting schedule
Job Product Date
### ##### ####
### ##### ####### ##### ####
Trigger pointActual Painting Yield
Job Product Date
### ##### ####
### ##### ####### ##### ####
Apply planned painting date asplanned requirement date of parts
Assembly point
eKanban automate creation and triggered signal
eKANBAN
Part Job Date
### ##### ####
### ##### ####### ##### ####
Automatic signal to deliver parts
Trig Signal Date
Yes ####
No ####Yes ####
Plan Need to deliver
Delivery of parts
Deliver parts with triggered signal (post goods issue to production order)
For parts preparation
OpenProdOrd
eKANBAN Material Supply
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Shop-floorprocessing
Productionorder
Pick accessories
and record qty.
Deliver material
to requiredwork center
Yieldconfirmation atthe trigger point
Acknowledge
andarrangement
eKanban
items for
accessories byS/N
Picking ListNo.xxxx
Post GI to order
for deliveredmaterial
Picking ListNo.xxxx
Stores
Signal
eKanban to
deliveraccessories
Generate
Picking noand print
Planning and Production
Yield
confirmation at
the materialusage point
Verify work
done withGoods issue info
Manual trigger
for urgent
queue bypassjob
Unplanned
Material
RequirementProcessing
1
3
6
12
13
2
7
8
9
10
11
4 6SAlternative
MaterialProcessing
5
Change storage
location ifnecessary
eKANBAN Material Supply
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Select an
alternative
material
Alternative Material Processing
Change
All /Somereq .qty?
All
Originalcomponent
item isflagged delete
Alternative
Comp. item isadded
eKanban for
alternativematerial isinserted
Original
component req.is reduced
Some
Further step of
eKanbanmaterial supply
eKANBAN Material Supply
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Unplanned Material Requirement Processing1
2
3
4
5
6
7
Fill in Req. Form
By Worker
with prod.ord andreason for movement
Sign approve byMgr./ Line LD/ Unit HD
Unplanned
Req. Form
Pick material and record qty
in Req.Form
Post GI to prod.order
with reason for movement
(MB1A/MIGO)
Submit approved Req.form
to store
Deliver material to shop-floorCopy Req.Form
With Issue Qty
Review MRP by MRP planner
Reason for Movement:
01: Tear/Broken02: Poor Quality
03: Lost
04: Rework
11: Sample Product w/o BOM99: Other Reason
eKANBAN Material Supply
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Person in charge for eKanban Work processingProcess / Function Responsible by Note4.Altenative Material Supply Chain5.Unplanned Material Requirement Production Worker6.Yield Confirmation at trigger point Production Support Every hour / 24 hours a day 6S.Manual trigger for urgent queuebypass job Production SupportMaterial Preparation7.Change storage location ifnecessary Both stores that keep theaccessory13.Verify work done with goodsissue information Production Support
Person in charge for Unplanned material requirementProcess / Function Responsible by Note7.Review MRP by MRP Planner MRP Planner
eKANBAN Material Supply
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Form and Report List
Form / Report Name Type Fill-in or Print byUnplanned Requirement Form Form WorkerPicking List Report StoreeKanban material requirement list Report For all concerneKanbanPlanned delivery summary Report For all concernParts Readiness by Work Center Report For all concernUnplanned Material Usage Summary Report For all concern
eKANBAN Material Supply
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eKanbanMaterial Requirement ListDeliver material to Finishing WS lean line bldg.2
Material Qty To produce Order Triggeddate Triggedby Supplyfor Plannedreq. date
1200100 Fin AAAAAAAA 2 ea Surf Lite A, SN 12 11039 05.08.13 PAINT034 FINSH04 05.08.131200200 Fin BBBBBBBB 1 ea Surf Lite B, SN 7 11083 05.08.13 PAINT034 FINSH04 06.08.131201300 Pad FFFFFFFFF 2 ea WS ASA G, SN 43 11024 05.08.13 PAINT023 FINSH12 07.08.131201400 Pad GGGGGGG 1 ea WS ASA T, SN 21 11109 05.08.13 TRIM029 FINSH12 07.08.131201800 Sticker SSSSS 1 ea WS CUST U, SN 6 11087 05.08.13 TRIM032 FINSH09 11.08.131201800 Sticker SSSSS 1 ea WS CUST U, SN 7 11204 06.08.13 QC5-043 FINSH13 05.08.13
eKANBAN Material Supply
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eKANBANPlanned Delivery Summary
eKANBAN Material Supply
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Parts Readiness by Work Center
eKANBAN Material Supply
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Unplanned Material Usage Summary
eKANBAN Material SupplyeKANBAN Material Supply
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eKANBAN Material Supply
Project Plan - Task Feb-2014 Mar-2014 Apr-2014Conceptual DesignDetail DesignProgram Coding 24/02/14 12/03/14UAT and User Training 13/03/14 15/03/14
Data and Resourcepreparation
3/03/14 15/03/14
Go-Live - Trial Run (Fin) 17/03/14 10/04/14Roll-out to all types ofaccessories 16/04/14
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Trial Run Plan
-Start at Fins store to supply for all areas
- Trigger Point Painting Material Finishing- Collect Job-ticket Scan barcode Yield Paining ( Yield Painting )- Store Fin Accessories
-Cutover plan how-to? To be discussed next week
Data and Resources Preparation
-Material groups for trial run-Reason for MovementProject Team
-Unplanned Material Requirement FormProject Team
-Update all painting work center as milestone operation
-Team and how to confirm yield at trigger point in every hours
-BOM verification for accuracy of allocated Fin
eKANBAN Material Supply
KANBAN M i l S l
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Budget Amount (THB)
eKANBAN Material Supply