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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

    l l

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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

    i l l

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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


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