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

FG Item Defining Process

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.
Problems
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

Routing Defining Process

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.
Problems
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.

BOM Defining Process

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.
Problems
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.

FG Inventory Control Process

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.
Problems
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..

FG Inventory Control Process

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.
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.

BOM Inventory Process Control

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.
Problems
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.

WIP Inventory Process Control

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.
Problems
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.

Stock Transfer Process Control

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.
Problems
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.