material management for industrial electronic

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

34

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.


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.


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.


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


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




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




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




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.


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




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.




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.




Is the material stock management activities and control and achievement against.

4. Inventory Management


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)



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)



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



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



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


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


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


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


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


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


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


3. Working Time (Weekly)


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


4. Working Time (Monthly)


6. Equipment is often used 1Material2Methode3Man4Machine

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 : [email protected]

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)

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