FG Item Defining Process Routing Defining Process BOM Defining Process FG Inventory Process Control BOM Inventory Process Control WIP Inventory Process Control Stock Transfer Process Control

Activities Get the Information of New Item from NMD like Customer Name, Customer part no. FG size, Process Details and Resource allocation. Item Defined in Inventory and assigned in Organization as per requirement. Check the Item attributes of Master Organization for Order management, for Routing and BOM. Define Item Categories and Planning Categories. Send Item Information to AR Department for Sales Price Updating.FG Item Defining ProcessProblems Incomplete or Wrong Information in Sampling Plan. Direct Sales or Stock transfer not clear for sales Organization. For defining item Category, information's not received.Countermeasure Need to Re-Develop MWT System Need the Master Data cell from Marketing, NMD, SCPL, Account, to gathering correct information on time, which will help to reduce execution time

Activities Collect details e.g. Process to be done, Resources, APS, Yield. Make Template as per Manufacturing Process and update Primary and alternate resource. Define Target Yield, Target APS & Power, Resource wise Process Wise. Define Completion Sub-Inventory as per sales Org. conformed by A/c Dept.Routing Defining ProcessProblems New Models Targets Yield and APS not confirmed until or unless one or two run not completed. Except Bending, other process Primary resource details not received. Sub-Assembly details like Assembly type and Location of Assembly not confirmed in sampling plan.Countermeasure Sampling Plan Information format should come with all Details Details of Sampling plan should come through MWT system Communication Gap need to improve.

Activities Collect details for BOM Part details from NMD. Collect Standard consumption of BOM parts from Production process wise. Define the Bill of Material process wise. Define the Source sub-inventory and Locator for Operation Pull and Push.BOM Defining ProcessProblems BOM details from NMD not available, only on demand it is received. To open the BOM item code the providing BOM details channel is lengthy. Standards BOM parts Item code not define on time, like RM, PVB & other child parts. After getting details from NMD execution for defining BOM part no dedicated Person allocated for doing these activities. First Lot of any New Consumable, received against Expense item, due to that consumption didnt come through WIP transactions.Countermeasure Need Dedicated person for completion all child part and standard BOM part activities in NMD, MPC. Details should float through MWT system so that delay can noticed. Tentative consumption results should come automatic from Production.

Activities Completion of Job Order based on Production declared at final Inspection. Isolate OK and Re-Inspection OK Transaction done as per records. Barcode Generation for Finished Goods and Physical transferred Material scanned at FG Warehouse in relevant sub-inventories Based on FG Goods Scanned at FG warehouse the same quantity net from Shop floor sub-inventory. Based on Sales Order Booking task updated and material drop through Hand Handle Device for dispatch.FG Inventory Control ProcessProblems Off line Mfg Transactions and Barcode generation did not gives correct inventory information for Shop Floor. Due to wrong Barcode generations QCFG inventory always shows wrong inventory. Lotout transactions not done by QA. Due to wrong Invoice, Wrong sales order and unreserved material Staging sub-inventory gives wrong information. No dedicated person is allocated for AFM inventory control. Miscellaneous Transaction done at the time of criticalities of FG unavailable. Continue to next page..

Countermeasure To avoid the offline transaction in Mfg need to re-install MNUs, which is failed due to infrastructure was of poor quality. To avoid the wrong barcode generation need one intermediate form instead of direct hit QCFG inventory after generation of barcode. Need dedicated person to look after all Lotout transaction in QA. Need to put more efforts in Dispatch to avoid the mistakes and should not by pass system in case of criticalities, need one person in AFM for looking all Inventory transaction. For On-line re-inspection, information should come in operation records and non-regular models re-inspection plan should come in advance. FG Isolate records should generate. Lotout on FG glasses in warehouse should avoid. Problems For Re-Inspection models Re-Inspection done On line and records not received Non- Regular Re-inspection Models rejection not punched. FG Isolate Inspection done but records missing. Lotout done in FG Warehouse, Reject material taken from Incomplete to complete the pallet but no recording facility to punch the rejection.

FG Inventory Control Process

Activities Consumption Booked for BOM item through WIP transactions. Consumption checked on weekly basis. Issue and return transactions checked on weekly basis. System On hand match with Physical stock once in a month. Gaps adjusted after reconciliation of stock System Vs. Physical.BOM Inventory Process ControlProblems Off line transaction by RM Ware House and Store due to PO pending. Wrong stock received for child part BOM materials from Shop floor. Wastage of Child part at information due to expiry or other reason not received Rejected Part re-used in lam plant, information not received. Alternate child part used but no information received through records. Dead stock or slow moving stock of any child part not received from. BOM part received against Expense item due to that exact consumption didnt captured.Countermeasure PO should be in Advance for BOM part, Stock should taken correct at S/F. Wastage of BOM parts should capture at S/F, Re-use of rejected material and alternate child uses information should come in records BOM part should purchase against its original code.

Activities WIP transaction done process wise step-by-step on shift basis. Operation pull item (like PP, DR,PR and standard child Part) consumption done with move transactions on line. BOM part which can vary, is consumed separately (by push) on shift basis. Checked all transaction on shift basis. Every Week WIP stock taken and match with system stock.WIP Inventory Process ControlProblems Operation records got incomplete for time breakup and Rejection breakup. Inner outer glass cutting done with different combination but loaded with different combination while bending, which is cause of stopping transactions. While tacking stock identification of WIP glasses not done properly. For missing WIP stock which is highlighted in IRA, no reason received from shop floor. Countermeasure Need to educate the operators for making operation records properly as well as process training. More focus required for missing inventory in between two processes. To resolve the WIP IRA Shop floor involvement required.

Activities Inter Unit transfer from transfer Organization as well as sales done. Release PO for Stock transfer material, and make MRN against RMINPUT. Update all taxes in MRN for taking Modvate. If Stock transfer have required any process then issued Input item to shop floor, if Not then issued out against Inventory Charge account. IF Process Done then after completion of process Barcode generation, if no Process Done then Production declared directly in FG W/S Sub-Invt. Stock Transfer Process ControlProblems Stock transfer plan not shared with receiver. Due to lack information PO cant make in advance. For sending Cut glasses not process as on today, for consuming the WIP inv. For making stock transfer of consumable actual item code is not used for making invoices Qty or Bill of stock transfer material doesnt match.Countermeasure For stock Transfer window person has to inform to all concerns. Need process for sending and accounting of Cut glasses. All stock transfer item code need to make invoicable.

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