P7 FLEXIBILITY INTRODUCTION

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2 P7 FLEXIBILITY INTRODUCTION Flexible Manufacturing is a systematic establishment where the operation will be able to react positively in the case of changes, whether predicted or unpredicted.

3 P7 FLEXIBILITY FLEXIBILITY CATEGORY 1 st Category : Resources Flexibility The system s ability to change to produce new product types and ability to change the order of operation executed on a part. 2 nd Category : Routing Flexibility The ability to use multiple facilities to perform same operation on part, as well as the system s ability to absorb large scale changes, such as in volume or capability.

4 OBJECTIVE & BENEFITS 1. Optimizing Human Resources Capabilities 2. Maximizing Usage Of Machines And Tools 3. Optimizing Process Capabilities 4. Maximizing Usage Of Material

5 OBJECTIVE & BENEFITS 1. Optimizing Human Resources Capabilities FMS will drive the organization to develop multi-skills employees where employees have ability to perform various job functions or processes. With multi-skills employees, every organization is able to : Fulfill any vacancy in the management or operation within short period. Improve on-job training efficiencies. Reduce man-hour loss time due to skill learning processes. 209

6 2. Maximizing Usage Of Machines And Tools With the implementation of FMS, the organization will indirectly encourage development team to continuously determine existing facilities and resources capability when conduct new product or process development and able to : Improve design capability input. OBJECTIVE & BENEFITS by improving design concept Eliminate purchase of unnecessary or unutilized machines and tools. Reduce cost of machines and tools management.

7 OBJECTIVE & BENEFITS 3 Optimizing Process Capabilities FMS will determine approved alternative processes (manpower, machine or tool, material and method) when failure of standard processes occurred. Availability of processes 4M elements successor plan will : Minimizing processes from stoppage caused by 4M factors. Conduct systematic training program. Provide on time preventive and plan maintenance. 211

8 OBJECTIVE & BENEFITS 4. Maximizing Usage Of Material Material can be determined as packing material for raw material, parts from suppliers, work in progress parts, sub process parts or finish good parts. Commonization of these material will resulting : Reduction of material storage management cost. Less control standard and minimize human error. Eliminate purchase of unnecessary or unutilized packing material, rack and others.

9 P7 FLEXIBILITY Resource Flexibility Product A OP5 Product B Product C FLEXIBILITY CATEGORY EXAMPLE OF NON FLEXIBLE SYSTEM Product ABC OP5 Product BC Product B EXAMPLE OF RESOURCE FLEXIBLE SYSTEM OP4 OP4 OP4 OP4 OP3 OP3 OP3 Dedicated machines and lines OP3 OP3 OP3 Multi operational machines. OP2 OP2 OP2 Limited Skills operator. skill of operator OP2 OP2 OP2 Multi skills operator. OP1 OP1 OP1 OP1 OP1 OP1

10 P7 FLEXIBILITY Routing Flexibility FLEXIBILITY CATEGORY Product A OP5 Product B Product C EXAMPLE OF NON FLEXIBLE SYSTEM Product A OP5 Product B Product C EXAMPLE OF ROUTING FLEXIBILITY SYSTEM OP4 OP4 OP4 OP4 OP3 OP2 OP3 OP2 OP3 OP2 Dedicated machines and lines Skills operator. OP3 OP2 OP3 OP2 OP3 OP2 Dedicated machines and lines eg. :. When volume for Product A,B drastically increase and the bottle neck are OP1~3, Line Product B shall be able to support at any time. OP1 OP1 OP1 OP1 OP1 OP1

11 P7 FLEXIBILITY RESOURCES RESOURCES WORKER RAW MATERIAL MACHINE AND TOOLING MANUFACTURING METHOD ENVIRONMENT KEY FLEXIBILITY Able and ready to perform many processes processes when required. I.e Multi skills. Fully utilize raw material. I.e More stamping parts can be produced from same types of coil. Being set up or design to maximize utilization by considering multiple parts or products to produce Able to meet production requirements such as increasing or decreasing of volume by auto adjusting processes. Provided space areas that minimizing processes re-layout cost when required due to drastic changes of volume.

12 P7 FLEXIBILITY FLEXIBILITY INITIATIVES 1. Mix Model Production 2. Kitting 3. Enterprise Resources Planning (ERP) 4. Single Minute Exchange Die (SMED)

13 P7 FLEXIBILITY EFFECTIVE DESIGN 1. To ensure FMS function effectively, a group of engineer shall be formed and this group normally called industrial engineering group. 2. Selected engineers shall have a knowledges with manufacturing processes and core resources. 3. Important tools applies for fms designing are : 1. Process FMEA 2. PDCA concept 3. VA / VE 4. VSM 5. Lean manufacturing 6. Kitting system ( if necessary )

14 218 Kitting System

15 Kitting Supply System L1 Kitting supply system is one of the systematic material supply methods use - From material storage to production line. Kitting is suitable for production line which : - Comprises of many processes - Assemble of many parts or components - Need high efficiency of producing output - High potential of miss assemble Advantage of Kitting: Potential to maximize productivity by : - Focused operator to their work scope - Consistent machine operation - Efficient material supply system - Process ownership methodology - Harmony working environment 219

16 Objective of Kitting Supply System L1 The objectives of kit supply applications: Minimize operator movement. Increase process ownership. Develop workers to work with similar rhythm and consistently productive. Eliminate miss-assemble product from being released to customer. Eliminate shortage or excess parts from being supplied to production. Productivity improvement control. Improve 5S condition.

17 Basic Flow and Supply Station L1 a) INCOMING PART SUPPLY STATION 1. Supply Bucket 2. Supply Trolley b) KIT PREPARATION STATION 1. Kit Part 2. Kit Bucket 3. Kit Trolley c) KIT SUPPLY STATION 1. Kit Rack 2. Kit Stand 221

18 Kit Supply System Implementation Activity L1 1. Study schedule 2. Current parts flow 3. Kit supply parts flow 4. Kit Supply component definition 5. Factors of 4M 6. Introduction method 7. Concrete idea and benchmarking 8. Study case 9. Cost estimation Other obstacles

19 Kit Supply System Implementation Steps L1 223

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21 Definition of Kitting System Kitting supply system is one of the systematic material supply methods use - From material storage to production line. Photo

22 Kitting system Kitting is suitable for production line which : - Comprises of many processes - Assemble of many parts or components - Need high efficiency of producing output - High potential of miss assemble

23 Objectives of Kitting system The objectives of kitting supply applications: Minimize operator movement. Increase process ownership. Develop workers to work with similar rhythm and consistently productive. Eliminate miss-assemble product from being released to customer. Eliminate shortage or excess parts from being supplied to production. Productivity improvement control. Improve 5S condition.

24 Basic flow for Kitting system Material handler INCOMING PART SUPPLY Kitting operator ARRANGE CHILD PARTS INTO KITTING BIN/RACK ACCORDING TO REQUIREMENT Kitting operator ARRANGE PARTS ONTO KITTING TROLLY Material handler SENT TO PRODUCTION LINE/ WORKSTATION Production operator PRODUCTION USE THE PARTS

25 Basic flow for Kitting system Incoming Part Arrange part into kitting rack Arrange on the trolley Sent to production

26 Implementation Activity for Kitting system 1. Study current schedule 2. Get current parts flow 3. Design kit supply parts flow 4. Design Kit supply component 5. Study on 4M factors 6. Introduction method to user/line 7. Check on implementation 8. Prepare standard operation procedure (SOP) 9. Training & Handover

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28 Definition of SMED Single Minute Exchange Die is also known as Setup Reduction and also known as Quick Changeover. SMED is one of the Lean Manufacturing activities with main objective is to eliminate waste. It is a method for rapidly and efficiently converting a process from running the current product to running the next product within less than 10 minutes. SMED was originally developed to improve machine tools setups, but it principles applied to all type of processes.

29 Benefits of SMED Set up can be done quickly, it can be done as often as needed. Simpler set up results in safer changeover, with less physical strain or risk of injury. Less inventory in workplace, which make production easier. Set up tools are standardized and combined, which means fewer tools to keep track of. Company can run products in smaller lots.

30 Basic flow for Implementing SMED Phase 1 Form the team. Study the setup process Conduct training and education Can use video tapes Phase 1 Phase 2 Phase 3 Classify into internal setups and external setups. Improve internal setups Improve external setups Operation which do not add values to the setup. Eliminate the waste. Reduce internal setup by doing more work externally Simplify or eliminate the need for adjustments and tweaking

31 Basic flow for Implementing SMED Phase 4 Develop the standard operating procedure (SOP). Evaluate the performance. Fine tune all elements of the setup by training the operators and timing the new setup process.

32 Die storage Forklift/ Lifter for Die transfer Overhead crane transfer coil Die standby Cushion pin storage Coil standby Raw material standby Basket Standby Die board standby

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35 ERP system

36 Agenda 1 Introduction to ERP 2 Why Company Choose ERP 3 4 Benefits Market Demand for Graduate Student 5 Implementation of ERP 6 Conclusion

37 A way to integrate the data and processes of an organization into one single system Delivers a single sharing database that contains all data for the software modules which would include: Manufacturing Supply Chain Management (SCM) Financials Project Management Human Resources Customer Relationship Management (CRM) Others: Access Control Customization (Tools) 241

38 2. Why Company Choose ERP All business activities & transaction are integrated in one system All level can access the data in one source Real time data. Related party can access latest info for planning Easy maintenance Better analysis & planning i.e inventory, manpower, logistic

39 Single point of entry One database for all users Improve order tracking Purchase Order : PO issuance -> Inventory receipt -> Costing Sales Order : Order acceptance -> Production -> Delivery -> Invoicing Increase process efficiency Eliminates manual job and promotes automation Save enormous time and effort in data entry Data accuracy Reducing error as data need only be entered or updated once Data such as inventory and ordering will be more reliable Immediate information Faster data lookup Increase productivity Time and resource are shifted to innovating, problem solving and direct service to customer Improve planning and forecasting

40 4. Market Demand for Graduate Student Future Career 1. Most Manufacturing Company looking for ERP solution Trend of IT in MFG 1. Value added (new skills, knowledge) 2. High capability to see manufacturing process 3. Enhance problem solving skills& analysis

41 CENTRAL SYSTEM PHN16 Server SCM MFG CRM TOOL S INPUT ERPLN OUTPUT Eg: 1.Sales Order 2.Purchase Order PRO J FIN HR Eg: 1.Delivery Order 2. Payment 3. Reports MECHANISM 1. Auto upload 2. Barcode 3. Manual 245

42 Triton Baan 5c A: Finance Module B: Distribution Module C: Manufacturing Module Barcode Customized System ERP LN Infor Barcode System nd Qtr A 3 rd Qtr B 4 th Qtr C IT Department, December

43 Records general transactions i.e. Accruals, provisions, adjustments and reversals. Records customers billing, invoicing. Updates customers details, payments. Review customers aging Records suppliers billing, invoicing. Updates suppliers details, payments. Review suppliers aging. Department s monthly budget analysis and control. Fixed assets register update monthly budget analysis and control.

44 Finance ERP Integration Pricing - Business Development update selling price for invoicing at Finance Standard Costing - Engineering Dept charge rate for Standard Costing calculation Finance Logistics - Finance create sales order. Logistics convert delivery order for invoicing. Purchasing - Procurement create purchase order for materials. Logistics convert received for payment process at Finance.

45 Modules Finance Warehousing Sales Procurement Manufacturing Enterprise Planning Invoicing Tools User F&S SCM F&S PVD SCM, Mfg, Engineering, BD SCM F&S IT IT Department, December

46 ERPLN MODULES USER DEPT Order Mgmt Warehousing Manufacturing Finance F&S, PVD SCM SCM F&S Sales Order Invt NA Customer Order Create SO Check Invt. Bal Invt Available Delivery Order Delivery Create Prod Ord Sales Delivery - DO Production Billing Purchase Order Release to warehouse Material Check Invt. Bal Create PO Receipt DO Production AP IT Department, December