Post on 03-Aug-2015
Overview Material as Primary
Materials ManagementWork Management
Human Resource Management
The equipment is often used
M. Rais Rahmat Razak
MATERIALS MANAGEMENT FOR INDUSTRIAL
ELECTRONIC
BEKASI, 14 January 2015
12
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1. Overview
Material is one of the four essential pillars of industrial management (Materials, Methods, Human and Machine) that will support the success or failure of operating a factory.
Materials Management (MM) is widely used in the electronics industry, with a high degree of variation in either of the type and size parts.
The level of competition primarily for the production of electronic Assemblies large factories encourage the growing popularity vendorisasi system, so it affects the material control system.
4Machine3Man2Methode1Material
2. Material as Primary
Experience shows, Cost of production in the electronic industry mostly in the material, ranging from 50 to 80 percent.
In the environment of electronic factory, the material has always been a good benchmark in determining the production plan and in deciding a management policies such as overtime or time off.
Manufacturing productivity can be increased if the supply of material smoothly and there is no shortage of material disruption.
The quality of the final result of production is determined by the quality of the supplied material.
4Machine3Man2Methode1Material
3. Materials Management(MM)
MM (Materials Management) governing the management of the overall material by focusing on material control.
Good material management will greatly benefit the company and vice versa unfavorable material management will provide disaster for the productivity of the company.
4Machine3Man2Methode1Material
MM has a strong connection with the production Planning, QC, purchasing and all of them can be integrated in the system managed MRP (Material Requirement plannin) are used as the base material management.
The material has a high degree of mobility, both incoming and outgoing materials and highly influential in the work of material management.
4Machine3Man2Methode1Material3. Materials Management(MM)
1. Grouping Materials
Material grouping by function and size
Mechanic
Electric
Total Assy
Material JIT (Just In Time)
Materials are items directly used in the production process such as components, materials JIT, PCB assy, sub assy, Deck assy as well as raw materials.
4Machine3Man2Methode1Material3. Materials Management(MM)
Materials Mechanic,
is a material that is classified as function are associated with functions such mechanic screw, spring, cover, baracket and others
2. Materials based on function and size
Packing system:Polybag, box, pallet
Size materials: Small, medium
4Machine3Man2Methode1Material3. Materials Management(MM)
is a material that is classified as a lot to do with the electric function such as resistors, capacito, connector, IC and others
Material Electric,
Party responsible for electric material also control the material that is classified in the raw materials such as solvents, the use of solder wire is widely used in the PCB assembly line.
Packing system:Polybag, can, box, pallets
Size material: Small, medium
4Machine3Man2Methode1Material
2. Materials based on function and size
3. Materials Management(MM)
Material Total Assy, is a material that is classified for many functions related to assesori completeness as is the case with manual book, labels, etc.
Packing system:Polybag, box, pallets
Size material: Small, medium
4Machine3Man2Methode1Material
2. Materials based on function and size
3. Materials Management(MM)
material is grouped because of their size using broad space, handling process with the rack and the frequency of such movements often, Top Case, Front pannel, PCB assembly
JIT Materials,
Packing system:Rack, Trolly
size: LargePacking/Handling: Rack
4Machine3Man2Methode1Material
2. Materials based on function and size
3. Materials Management(MM)
3. Based on the Work Area
Issue Part,
Stock Material
PMS/MRP Production
Plan
Bill of Material
Purchase Order
Dewarehousing Plan
Delivery Notice
Etc.
Simulation system
Activity Check Point
Arrival Lot Issue Material Non JIT, D-7 Production Total Assy
The latest production plan of the Departement of Planning
Lot Issue Expenses Non JIT material, D-3 Production Total Assy
Make sure Bill of Materials correct and updated technical changes
Issue Lot JIT material expenditures, D-1 Production Total Assy
Check the quality of the material visually or by using a tool
is the beginning of the material management process with the process of normal Issue on software systems. Production lot number of production plans will be at issue in the system for the next 7 days and will be a benchmark and guidance in the subsequent process.
4Machine3Man2Methode1Material3. Materials Management(MM)
Incoming Materials,
Activity Inspection
Receive documents Letter Qty actual with documents
Place in the arrival area Handling system, packing system
Forward to IQC Check the quality of the visual material or with tools
Input documents Letter Ensure that part no and quantity inputted correctly
Material Move to an area of OK. incoming Handling dan Packing system
is, an area that is prepared to put all the new material coming and prepared in check. Activity material officer is counting incoming goods and matched with the letter documents.
For JIT material, check the production planning D minus 1 day
4Machine3Man2Methode1Material
3. Based on the Work Area
3. Materials Management(MM)
Warehouse,is an area for storing the material before it is issued to the production department or departments to the Vendor. Activity material officers are storing materials in accordance with the area, part numbers and standard accumulation of goods.Activity Inspection
Move material from the incoming area to Warehouse
Handling, Packing system
Place the material as part No. Check quantity and area, note the buildup standard
Note the storage standards standard buildup
Cros check the letter document and Incoming mail by the system
Quantity dan part number same
Write a stock card Calculate, data is the same as the system
For JIT material, place the shelf material in the path specified in the order of production.
4Machine3Man2Methode1Material
3. Based on the Work Area
3. Materials Management(MM)
Dewarehousing,is an area for storing the material before it is issued to the Ministry of production or to the Vendor. Activity material officers prepare the goods according to plan daily expenditures.
Activity Inspection
Receive Daily Material Expenditure Plan Lot No. selected in accordance with the order of the production plan
Sort the data material expenditures by part number and quantity of his number
Check the amount of material consumption per production sets, see the BOM (Bill of Materials)
Prepare materials in accordance with the part number and Quantity
Check the packing standard per part number
Move materials to area dewarehousing Periksa Handling dang packing system
Serah terima material ke Departemen produksi atau vendor
Cros check documents and actual
Create dewarehousing report, write a complete lot of data and material shortage
Make sure the part number per complete production model, data recap material shortage.
JIT material, place the rack material in the path specified in the order of production.
4Machine3Man2Methode1Material
3. Based on the Work Area
3. Materials Management(MM)
Is the material stock management activities and control and achievement against.
4. Inventory Management
4Machine3Man2Methode1Material
Issue PartInventory amount (USD) Daily, Weekly. Standard issue production lots; Non JIT D-7, D-3hari JIT materialMonthly Closing planning strategies;
Arrival Status material KIT (import)Standard incoming local materials & JIT itemsMapping allocation of stock (outstanding, incoming,
warehouse, working in process).Age arrival of materials; 30 days, 60 days, 90 daysData Destruction material
Target: Stock card (actual) = stock IT (systems)
3. Materials Management(MM)
4Machine3Man2Methode1Material
Warehouse area, the control status of the stock; Croscheck quantity of card stock with the IT systems, the daily.
Quality trouble, Engineering change trouble, Separation of stock status 30 days, 60 days, 90 days,
Standard storage, useless stuffDewarehousing, the control status of the stock; Handover of materials to production or other departments
Appropriate placement area dewarehousing
4. Inventory Management
Incoming area, the control status of the stock;
outstanding receive, quality trouble, IT system trouble, Trouble planning (beyond standard incoming plan)
3. Materials Management(MM)
4Machine3Man2Methode1Material
What special request materials from other departments.
Why Trouble quality or missing material that occurs in other departments.
Who Production Department, Vendor, QC, Planning
When Can be done after 1 pm each day
Where Addressed to the Department of Materials Management.
5. Special Issue
3. Materials Management(MM)
4Machine3Man2Methode1Material
6. Common Problems Materials
Stock data card is not the same as the IT system Distribution Issues sheet latePreparation of goods lateMaterial missingDamaged materialNot according to the standard buildupNot according to the standard packingMany stock unusedStock longerShortage many material itemsWork Accidentwarehouse on fire
3. Materials Management(MM)
4Machine3Man2Methode1Material
7. Performance Measures
Data Card Stock = Stock IT systemUnloading, acceptance of material quicklyDewarehousing, fast serviceNo material is lost, damagedEfficiency of utilization of the area and equipmentFast and accurate reportingContinuous improvement
3. Materials Management(MM)
4Machine4. Work management
Work management or system that is widely used in Materials Management
IT-system : Production Managemen system (PMS) Or ERP•MRP (Material Requerement System)
•Issue Sheet
•5 R (Rapih, Rawat, Resik, Ringkas, Rajin)•JIT (Just In Time System)•FIFO (First ini First out)•TFT (Task Force Team)
1Material3Man2Methode
•Friendship Meeting
Structuring Warehouse
Development of Human Resources
Incoming Plan
acceptance
examination
StorageControl
Dewarehousing
Issue Process, IT
system
1. Internal Department of Materials Management
4Machine 1Material3Man2Methode4. Work management
4Machine
2. Other departments
Planning Department
1Material3Man2Methode
Purchasing Departement
Quality Control Departement
The part that makes monthly production plan at the request of the Department of Marketing, and adjust the daily updating of material and production conditions
Making forecasting,Choosing a supplier who could prepare quality goods, cheap and can follow skedule standard deliveryMake purchases of materials according to the production plan,
Checking the quality of incoming materials, only goods OK (good condition) can be received in the IT system (IQC)Line Quality Control (LQC)Outgoing Quality Control (OQC)
4. Work management
4Machine
Vendor Departement
1Material3Man2Methode
Production Departement
Marketing Departement
2. Other departments
The part that controls the vendor or the companies that produce finished goods using material from the Material Management.
The main departments that receive material from the warehouse to be produced in accordance with production plans made by the Planning Department.
Sales section which gives the demand for manufactured goods to the Department of Planning.
4. Work management
3. Interconnection other parts, Control Materials based Lot Normal Production
Material Management
Plan Purchase QC Vendor Prod Marketing
IT Issue
Incoming
Warehouse
Deware-housing
2a 2b2c 2d 2e 2f
13
4
5
6
7
8
9a 9b 9c
1010a
10b 10c
Shortage material
Material Inspection comes
Material quality examination results
4Machine 1Material3Man2Methode4. Work management
3. Interconnection between parts, Control Based Special issue from other departments
Material Management
Plan Purchase QC Subcont Prod Marketing
IT Issue
Incoming
Warehouse
Deware-housing
1a
4
5
67
8
9
1b1c1d1e1f
2 3
9 99 9 9
4Machine 1Material3Man2Methode4. Work management
IQC
Input Data system
WarehouseMechanic part
WarehouseElectric part
WarehouseTotal Assy part
Dewarevendor
DewareProd line
Incoming area,Waiting Inspection
Componen NG
Arrival area
Dewarevendor
DewareProd line
Arrival JIT Material
Waiting Inspection of JIT item
Loading non JIT
Loading JIT Item
Transfer area
Transfer area
Transfer area
Transfer area
Issue to Production Line
Issue to Production Line
Transfer area
Production Line
4. Lay Out area Materials
4Machine 1Material3Man2Methode4. Work management
1Material5. Human Resource Management
Human Resources Management Materials controlled by a Manager of Materials in 6 parts work. Each section is led by an Assistant Manager in charge of some of the staff or officer material.Staff or Officer Material each have the responsibility to control the number of items that have been set by management material.
Material Management
Issue Part
Incoming Part
Mechanical Part
Electric Part
Total Assy Part JIT Part
4Machine 2Methode3Man
1. Structural Work
No. Activity Check Time Participant Host
1 Morning Briefing Attendance, work attitude
06.50~07.00 All employee
Manager
2 Re-Condition, storage 07.00 ~ All Charger
3. Meeting Manager Deware Plan 08.00~08.30 Mgr, Ass Manager
4. Print Issu Sheet 08.30~ Issu Part Ass. Mgr, Charger
5. Dewarehousing Issu sheet, shortage
09.00~ Ass. Mgr, charger
6. Meeting between the department
Shortage condition
11.00~11.30 Manager all dept
Factory Manager
7. Afternoon Briefing Work condition 15.00 All Manager
Ass. Manager may request Over time, 2 hours or 3.5 hours after 15.00
1Material4Machine 2Methode3Man
2. Working Time (Daily)
5. Human Resource Management
No. Day Aktivity Check In Charge Host
1 Monday Evaluation of IT System
Lot, qty weekly dewarehousing
Ass. Mgr Manager
2 Tuesday Implementation 5R, JIT, Fifo
storage All Charger
3. Wednesday
Discipline Work time, attitude
Mgr, Ass Manager
4. Thursday Evaluation of capacity Repairs, inovation Issu Part Ass. Mgr, Charger
5. Friday Claim from other department
Dokumen claim Charger Ass. Mgr, charger
6. Saturday Happy day Employee condition
Manager all dept
Factory Manager
1Material4Machine 2Methode3Man
3. Working Time (Weekly)
5. Human Resource Management
Weekly Aktivity Check In Charge Host
First Settlement of outstanding receive,
History of document
All Charger Ass. Manager
Second Monthly presentation Factory
deviation targets Manager Factory Manager
Third Inovation Plan the impact of innovation
All Charger Ass. Manager
Fourth Closing plan Time schedulle Manager Factory Manager
1Material4Machine 2Methode3Man
4. Working Time (Monthly)
5. Human Resource Management
7. Resource
M.RAIS RAHMAT RAZAK, IR, M.SiRoad 2, Bekasi Asri Residential Gardens Block B-9, RT01-RW029Pengasinan Village, Bekasi municipality (17115)Phone: +62(021) 081316142449e-mail : mraisrahmat@yahoo.com
SUMMARY OF QUALIFICATION•5 years Expereience,working with friends to manage their own business & Expert House of Representative (DPR RI) 2009 ~ 2014.
•2 Years Experience, Total Control Management Injection Plastic Factory.
•6 Years experience as, Purchasing and Materials Management Controller Production. (PT. LG Electronic Ind., PT. HIT Electronic Ind.)
•6 Years experience as, Controller Overall Production Management.
•2 Years Experience as, Management Consultant and Project Management Government.
•1 year experience as, HR (Human Relations) in the context of Quality Improvement of Industrial Relations at PT. LG. Electronic. The result is, making the Collective Bargaining Agreement between the Company and Employees.•Experienced in implementing ISO standards system, Management Representative.•Experienced in system development, especially in the construction of new factory. (PT. Taekyung Technology)