Material Handling - Accessories

8/12/2019 Material Handling - Accessories

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Proposed Solution

eKanban Material Supply

27-Feb-2014

by IT Department


2/18

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



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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



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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



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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



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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



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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



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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



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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



12/18

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



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eKANBANPlanned Delivery Summary



14/18

Parts Readiness by Work Center



15/18

Unplanned Material Usage Summary

eKANBAN Material SupplyeKANBAN Material Supply

l l


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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


KANBAN M i l S l


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Budget Amount (THB)


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Material Handling - Accessories

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