automation on non -feeders

21
LBI - Microsoft BA Supermarket Lean Flow Project Leads Dhivagar Rathinam-MF Team Members Chien Nguyen Van (GL-MF) , Minh Nguyen thi (GL- MF),Mahesh P (IT), Jiwak (Security) , Tero Overall Status Confidential Team Scope Material Flow , IT, BA Production ,Security. Key Deliverable Accurate inventory control for non-Feeder material , Automation Process, Lean ordering method. Accomplishments until now Upcoming Tasks/Activities 1. Kick off meeting conducted on 19 th July 2. Brain storming done on the Project 3. Case study 4. Min /max implementation completed 5. User local ID Print layout verified Starting with phase-1 ( ULID) Print implementation in recieveing Phase -2 (Storage record in Local user tool ) Phase -3 (Delivering through ULID Scan systems ) Phase -4 (Implementing ordering tool in BA Lines ) Phase -5 (Returning materials scanning and storing ) Trouble shooting errors and follow up Open Key Decisions (D), Issues (I), Risks (R), and Dependencies (Dep) Help Needed Consumption of Non-Feeder Materials In BA Line need to be studied. Required support from IE Team to study Lead-time and Document the Process Key Milestones Comple te Stat us Comments Creating Team / Brain storming Activity 19-Jul C Attached brain storming in next slide Min/MAX Implementation 01-Aug C Makes Auto replenishment Process Phase -1 Implementation and Verification 18-Aug G ULID Verification done , creating tool is ongoing Phase 2 / 3 Implementation and verification 29-Aug W Ordering tool Implementation in BA Lines 01-Sep W Returning materials scanning and storing 10-Sep W UAT Kick off for the Project 18-Oct W Observation and Trouble shooting 28-Oct W Status Legend: Not Started W Issues Exist, Will Impact Project R Y G Issues Exist, Mitigation Plan in Place On Track C Complete G Microsoft rPoint Presenta

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Page 1: Automation on Non -feeders

LBI - Microsoft

BA Supermarket Lean Flow Project Leads Dhivagar Rathinam-MF

Team MembersChien Nguyen Van (GL-MF) , Minh Nguyen thi (GL-MF),Mahesh P (IT), Jiwak (Security) , Tero Virtanen – Infra , Van Nguyen thi thu (BA-Prod)

Overall Status

12

Confidential

Team Scope Material Flow , IT, BA Production ,Security.

Key Deliverable Accurate inventory control for non-Feeder material , Automation Process, Lean ordering method.

Accomplishments until now Upcoming Tasks/Activities

1. Kick off meeting conducted on 19th July 2. Brain storming done on the Project3. Case study 4. Min /max implementation completed 5. User local ID Print layout verified

• Starting with phase-1 ( ULID) Print implementation in recieveing • Phase -2 (Storage record in Local user tool )• Phase -3 (Delivering through ULID Scan systems )• Phase -4 (Implementing ordering tool in BA Lines )• Phase -5 (Returning materials scanning and storing )• Trouble shooting errors and follow up

Open Key Decisions (D), Issues (I), Risks (R), and Dependencies (Dep) Help Needed

• Consumption of Non-Feeder Materials In BA Line need to be studied. • Required support from IE Team to study Lead-time and Document the Process

Key Milestones Complete Status Comments

Creating Team / Brain storming Activity 19-Jul C Attached brain storming in next slide

Min/MAX Implementation 01-Aug C Makes Auto replenishment Process

Phase -1 Implementation and Verification 18-Aug G ULID Verification done , creating tool is ongoing

Phase 2 / 3 Implementation and verification 29-Aug W

Ordering tool Implementation in BA Lines 01-Sep W

Returning materials scanning and storing 10-Sep W

UAT Kick off for the Project 18-Oct W

Observation and Trouble shooting 28-Oct W

Status Legend: Not StartedW Issues Exist, Will Impact ProjectR Y GIssues Exist, Mitigation Plan in Place On Track C Complete

Microsoft PowerPoint Presentation

G

Page 2: Automation on Non -feeders

LBI - Microsoft

Material Tracking system tool Implementation Projects Timelines

Status Legend:

Not Started WIssues Exist, Will Impact Project RIssues Exist, Mitigation Plan in Place YOn Track GComplete C

Action plan Jul Aug Sep Oct BA Supermarket Materials Lean flow -Non Feeder Materials W29 W30 W31 W32 W33 W34 W35 W36 W37 W38 W39 W40 W41 W42

1 Phase 1 : Kick start C 1.1 Review with cross functional Teams C

1.2 Discuss with team about the idea to make automated Tool to Record Materials Flow C

1.3 Cost Approval C 1.4 UAT C 1.5 Project result review W 2 Phase 2: Material Pull, Receiving and Put away

2.1 Min / Max Implementation For the Non-Feeder Materials

2.2 Implementing the Material tracking tool in the receiving area to Record the Reel by the Pack Qty C C

2.3 LID sticker layout and approval for Non -feeder Materials C W

2.4 Machines and Scanners required to activate process C 2.5 Training on the Process Review C W W 2.6 Implementation C W W 2.7 Follow up C W 3 Phase 3: Store and Review

3.1 Fixed Bins to be implemented to store Non-Feeder Materials C

3.2 Verifification on the Storing process accurate storage to bins C

3.3 Verification with MT Tool for correct storage and ensurance W

3.4 Training plan W 3.5 UAT W 3.6 Implement 4 Phase 4: Material Request tool

4.1 Eliminate Manual requests Logic Discussion W

4.2 Auto print in BFO , When BA Lines Required Non-Feeder Materials W

4.3 Request Will be stored in a Tool W 4.4 UAT W 4.5 Implement W 5 Delivery / HC Proposals

5.1 Delivery through MT Tool ( No manuals paper work) W 5.2 Lead time accuracy and Kititng accuracy study W W W W 5.3 HC To deliver materials (Transit materials ) W 5.4 Training to Security team W W W 5.5 Review W 5.6 Project implementation W 6 Follow ups W

D M A CI

Page 3: Automation on Non -feeders

LBI - Microsoft

Lean Six sigma Project Team Project : Automating Non-Feeder Materials delivery through Lean flow.

Name Role in project Working in Designation

Dhivagar Rathinam Project Manger Material flow Lead

Jiwak Shiradkar Project Initiator Loss prevention / Factory Security Lead

Kai Sunila Project systematic Planner Head of IT Head of dept.

Mahesh kumar Lam Nguyen Dinh Project systematic Designers MES Support Engineer

Van Nguyen Thi Thu Project Member (End user) BA Production Analyst

Tero Virtanen Project Member (Devices) Infra Structure Manager

Project executors (Shop floor ) Material Flow /Security team leaders

D M A CI

Minh Giang Dung Ngoc HA Chien

Page 4: Automation on Non -feeders

LBI - Microsoft

ID M A CProject Problem and goal Statement

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

Problem statement : Non-feeder material Delivery

Non-Feeder Materials manual delivery no proper accountability Inventory mismatch 0.5% In all Mini-PI & PI . Lean flow not maintained ( Bulk ordering method followed) No records of issuance and tracking

Goal Statement : Non-feeder material Delivery

Automating the delivery process through Local tool with “Zero” Cost investment Inventory mismatch reduction from 0.5% to 0% Ordering through tool for the required quantity. Recording the movements of material through Material tracker

Page 5: Automation on Non -feeders

LBI - Microsoft

ID M A CHigh Level Process Map - SIPOC

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

Supplier Input Process Output Customers

• Gets transfer order

• Picking

• Verifies

• Issue to MS BFO

• Handover

• Confirmation

• Manual Request

CEVA Document

• Receives Manual Request from Lines

• Verifies quantity

• Triggers Manual transfer Orders

• security Verification done

• Move to lines for production

BA Supermarket Materials

• Supplied to the Lines With manual transfer orders

BA Lines

• Receives the materialAnd resumes Production

CTQCritical to Quantity

• While receiving materials

• While storing Materials

• While transferring Materials

• While Delivering materials

Page 6: Automation on Non -feeders

LBI - Microsoft

Create Manual Transfer orders

Receives Order and Picks materials

Delivers to BA Supermarket

Verifies And Stores

ID M A CDetailed Process Map

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

BA Lines

BA Supermarket

CEVA

Security

Receives Pan

Receives Plan From Planning

Raise Manual request

SAP Stock visibility

Kit materials based on request and

system transfer done

Moves Physically to Security

Verifies and Chops

Receives Materials

Resumes Production

If balance after Producing

Get return in system and stores

Returns to BA supermarket

Verifies and allows

Page 7: Automation on Non -feeders

LBI - Microsoft

Process –FMEA

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

Potential failure and effect analysis Prepared By : Dhivagar Rathinam

FMEA Date Org : 19/08/2016

Process Step Key process input Potential failures

Potential failure effects

SEV Potential Causes OCC

Current Process

Controls DET RPN Actions

Recommended

What is the Process Step?

What are the KPIV’S ?

In what ways process fails to Meet

Requirement?

What is the impact on the

Key output variables ?

How severe is effect to

customer?

How could the failure mode

occur?

How frequent is cause likely to

occur

What are the Existing controls to prevent the failure

?

How possible is detection of cause

?Risk priority

ranking Action for

reducing and sustain?

Receiving the Materials from CEVA

through manual transfer order

Follow the MIS And follow

process with supervision

Human counting error and no record in manual receiving

amount (Individual owners )

Stock mismatch in BA

Supermarket , wrong

confirmation

8

No system records no regular

reporting system and lack of follow-up by supervision.

8Manual transfer

orders and physical

verification 8 512

Automating the Receiving process through SAP Min

max System

Storing and delivery the non feeder

materials

Follow the MIS And follow

process with supervision

Human counting error and delivering wrong

qty ,code

Stock mismatch in BA

Supermarket 8

No system records no regular

reporting system and lack of follow-up by supervision

6Manual transfer

orders and physical

verification 8 384

Tracking through a automated tool

and PDA Scanning systems

Manal ordering Process

Follow the MIS And follow

process with supervision

Lean flow on Ordering is Not followed and

over inventory in Production

Missing of materials in BA

Lines 8 No proper

ordering method 4 Manual document procedure 8 256

New ordering tool can be implement

based on requirement BA

Lines can pull materials

ID M A C

Page 8: Automation on Non -feeders

LBI - Microsoft

Data Collection Plan

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

ID M A C

Data collection Objective identify areas to analyze 

Non Feeder Material delivery Processes

"To collect data to" (purpose, goal or expected outcome) 

(process or product)

Ref #

What to Measure Develop Operational Definitions and How to Measure

Area : BA Supermarket / BA Lines

Operational Definition Sampling With Plan Collection

Measure Name Type Measure Data Type Stratification What How What Where When How ManyCollection Method Who collects

1 FMEA - 1 SAP MM Transfer order Categorical By Team Receiving the Materials from CEVA

through manual transfer order Through SAP Transfer orders

Loss analysisNo Proper Handover and confirmation Mismatch

leads to Stock inaccuracy BFO Receiving While receiving from

CEVA

All the Material Received through Manual Transfer

Orders

Manual transfer and confirmation

Operator BA Supermarket

2 FMEA - 2 SAP MM Transfer order Categorical By Team Storing and delivery the non

feeder materials Manual Documentation and

SAP Transfer orders Loss analysis

No Proper Storage method and delivery Process

Followed through Bulk mode and not in Lean

BA Supermarket While Storing in the BA Supermarket and delivering to BA Lines

All Non Feeder Materials

Now through Manual

documents Operator BA

Supermarket

3 FMEA - 3 Manual

Document and SAP Manual

transfer orders Categorical By Team Manal ordering Process Manual documentation and

Loss analysis No proper Ordering method as per Plan BA Lines

While material needed to Line for

Production All non -Feeder

Materials Through Manual

requests Operator / LL BA

Lines

Page 9: Automation on Non -feeders

LBI - Microsoft

Measuring the Process failure

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

Week 28 Week 29 Week 30 Week 31 Week 32 Week 33 Week 34 Week 35 Week 36 Week 37 Week 38 Week 39 Week 40

-60.00

-50.00

-40.00

-30.00

-20.00

-10.00

0.00

10.00

20.00

30.00

1 2 3 5 60 0 0 0 0 0 0 0

-28.53

-6.95

22

-54.43

-43.14

0 0 0 0 0 0 0 0

Non-Feedeer Material Mismatch Trend

Mismatch Cases Diff of Mismatch in €

Reduction on Non FeeederInventory Loss Project

Kick off / Brain Storming

ULID Implementation

Min/max

Ordering Tool

Completed On-Going

Training / Process Documentation

Implementation

Monitor and control Sustenence

Current

Mismatch Values

Mismatch cases

ID M A C

Page 10: Automation on Non -feeders

LBI - Microsoft

Week 28

Week 29

Week 30

Week 31

Week 32

Week 33

Week 34Week 35

Week 36

Week 37

Week 38

Week 39

Week 40

170 185

165

0000000

000

300250

250

217

000000000

Manual Transfer orders Data

Avg Manual TO From BFO-ceva Avg Manual Transaction to BA Lines

Measuring the Process failure

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

Avg Manual Transfer orders

To BA Lines

Avg Manual Transfer orders

to CEVA

ID M A C

Page 11: Automation on Non -feeders

LBI - Microsoft

Measuring the Process failure -Pareto

Status Legend: Not Started Issues Exist, Will Impact Project Issues Exist, Mitigation Plan in Place On Track Complete

Mismatch

cases

Manual

transfe

r Ord

er iss

ue

counting E

rror

Partnumber

mismatc

h

wrong d

elive

ry 0

2

4

6

8

10

12

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%11

7

4 4

2

ID M A C

High Impact on Mismatch

Page 12: Automation on Non -feeders

LBI - Microsoft

Cause and effect Analysis

Manual Ordering

Operator

BA Lines

Non-Feeder materials

Ordering process

Ordering with manual sheets

Waiting outside BA Supermarket to issue manual requests

Material pulled in bulk from ceva and no storing place in BA Supermarket

Physical Counting error

Material supplied to lines for one shift Qty , Over flow in BA Lines

Machine Cannot recognize the demand automatically

Ordering method Is random based on the requirement

Orders with Manual sheet Orders with Manual sheet

No Record

Manual Transfer orders

üü

ü

ü

ü

üü

û

ûûû

Material Mix-upü

ID M A C

Page 13: Automation on Non -feeders

LBI - Microsoft

Cause Analysis Solution discussed

Ordering reels With manual sheets No records and wrong kiting due to Manual wrong entry of Qty Ordering tool to be implemented in all the BA Lines Based on the MOQ ( Maximum Ordering Quantity )

Physical Counting Errors Due to partial Deliveries as per the Random requirements Given byBA Lines , BA Supermarket has inventory loss due to counting error Only MOQ Order Will be Followed

Ordering Method is Random Based on the Requirement No plan for the demand ordering For One shift twice Only material will be issued based on demand by ordering tool

Material Pulled in bulk from CEVA no storing place in BA Supermarket

Material Ordering is in Bulk due to reduction of Transfer orders and Resource Unavailability Min /Max Auto trigger will be enabled

Over flow of materials In BA Lines due to Bulk ordered qty No ordering for the requirements followed Based on the Particular line demand material will be supplied

Manual Sheet ordering Operators are Written up with manual sheets and come to BA Supermarket stand for handover it to BA Supermarket operators Only system ordering process will be implemented

No Records There is no records maintained fro the ordering and delivering process Local tool will be developed to make sure all are Recorded and used for future references

Mix-ups Material Mix-Up impacting the stock mismatch and Line stop Local ID Will be developed and scanned to the local tool to identify the correct material to correct order supplied

Brain storming ID M A C

Page 14: Automation on Non -feeders

LBI - Microsoft

Brain storming Idea Through Picture flow ID M A C

Process Plan in BA Supermarket for non-Feeder Materials and system flow

Page 15: Automation on Non -feeders

LBI - Microsoft

Data Collection plan for analyze ID M A C

Null Hypothesis Alternative HypothesesDescription data Type

Number of UAT Sample's

where to collect data

who will collect data

how will be the data recorded Owners

1 Physical Counting Errors

Does the Physical counting error

done wontedly or operator

negligence?

Manual Counting tends to a Human counting

error

manual counting doesn't the only reason for the

counting error

SAP Manual transfer order vs physical transfers

Location , delivery method , receiver's

acknowledgement , system transfers

13 SAP Shift GL Excel sheet Shift GL

2

Ordering Method is

Random Based on the

Requirement

Does the ordering method affects

the flow or Kitting ?

No, Bulk ordering helps to move the material

bulk to the requirement once in every 4hrs

yes, the ordering method is in bulk mode and not

reliable to the plan

ordering the non feeders

with manuals and transferred through SAP

Manual record and SAP System

transfers 15 SAP Shift GL Excel

sheet Shift GL

3

Material Pulled in bulk from

CEVA no storing place in

BA Supermarket

Does the ordering method affects

Storing ?

No, Bulk ordering helps to move the material

bulk to the requirement once in every 4hrs

yes, the ordering method is in bulk mode and not reliable to the plan and

no storing place

ordering the non feeders

with manuals and transferred through SAP

Manual record and SAP System

transfers 20 SAP Shift GL Excel

sheet Shift GL

4

Over flow of materials In BA Lines due to Bulk ordered

qty

Doest the materials

overflow affecting the BA Lines ?

No, its helpful to keep in a trolley and produce whenever we need

yes , its creating more overflow of stock and no lean method followed

SAP Transfers SAP 20 SAP Shift GL Excel

sheet Shift GL

5 No Records Does the records of transfers are

reliable ?

yes , its reliable but sometime we have

mismatch

No, it does not meet the matches in BA

Supermarket and no record of handovers

SAP Transfers SAP 20 SAP Shift GL Excel

sheet Shift GL

6 Mix-ups Does the

materials are mixed up where?

No, its not but sometime . Which part number are

more similar

yes , because of some part numbers are more

reliable Physical

verification SAP 10 SAP Shift GL Excel sheet Shift GL

DATA Collection Plan for "ANALYZE PHASE"

REFCauses to be

tested

List of questions that must be

answered to each selected cause

Statement and Analysis

Tool To be used

Data to Be collected

Page 16: Automation on Non -feeders

LBI - Microsoft

Data Collection and Analyze ID M A C

Cause Analyzed Week 29Week 30Week 31Week 32Week 33Week 34Week 35Week 36Week 37Week 38Week 39Week 40

Manual transfer oders from BA Supermarket to

CEVA 170 185 165

Receiving erros Errors 3 2 5 3

Manual transfer oders from BA Supermarket to

BA Lines 300 250 250 217

Mismatch cases 12 11 11 6

counting errors while transfer

materials 3 2 5 3

wrong transfers 1 1 0 0

Minmax Auto replenishment process implemented

Implemented LID Tool for ecieving Inventory team / Shift GL

Reported By

Inventory team / Shift GL

Inventory team / Shift GL

Inventory team / Shift GL

Inventory team / Shift GL

Inventory team / Shift GL

312

8

4

0

Page 17: Automation on Non -feeders

LBI - Microsoft

Improve Phase – Detail systematic planUI Design

ID M A C

Ordering logic

Materials picked for order id

BA Supermarket Security BA Production

Login

Order

Order Queue to pick

ORD_ID

Scan Order ID / LIDSo the material qty will assign

(Delivery process) scanning the materials matches the

ORDER ID

ORD_ID

Received_Qty

Confirm

end

System Updates like this

Non-feeder materials ordering method

Page 18: Automation on Non -feeders

LBI - Microsoft

Improve Phase – Detail systematic plan ID M A CUI Design

Production ordering system for Non –Feeders (User interface design )

1

2

3

Material Ordering client

1. Enter the Username / Password and the Line ID to enter ordering

tool 2. Only the user registered can login to the screen

1. Enter Part number , MOQ , And number of Pack required.

2. Click order Button , so BA Supermarket will get the Print of order

3. You have search Button to search your orders through LID Number

4. If you order the same material within One hour the below error will be displayed to make your more Cautious

1. Final step after getting your Order Delivered to lines scan the bar code and the Qty will appear automatically click confirm

2. Verify Physical materials 3. So you confirm the material

physically reached the BA Lines

Page 19: Automation on Non -feeders

LBI - Microsoft

Improve Phase – Detail systematic plan ID M A CUI Design

BA Supermarket order receiving system for Non –Feeders (User interface design )

2

3

Material order Queue

1. Enter the Username / Password and the Line ID to view the Screen

2. Only registered User can open the Tool

1. In this screen you can view the Order id and the material and qty requested by the Line

2. You have search Button to search the order ids based on lines

3. Once you scan the LID With the Order ID It will assign automatically ( See the first line item here )

1. Scan the Order id Picklist 2. Scan the LID.

1

Materia Picking client

Page 20: Automation on Non -feeders

LBI - Microsoft

Category Product Material

PWB CRYSTAL 9857961

Automating transfer orders example From BA Supermarket to CEVA

Category Product Material

PWB CRYSTAL 9857961

Improve Phase – before/ after ID M A C

# Key Factor Description (Muda's)Elimination

Improvement strategy

Solution Status Completion date

Owner

1Manual transfer orders From BA Supermarket to

CEVA

More Manual orders are triggered to CEVA Without

premeasuring the inventory level

inside BA Supermarket

Over Inventory

To avoid over inventory manual

transactions between BA Supermarket

and CEVA Need to be eliminated

Auto Min/max Method will be implemented

to pull the stock based

on rack capacity

automatically

Completed 5/08/2016 Dhivagar Rathinam

Before After Manual transfer orders example From BA

Supermarket to CEVA

Transfer order Number

From Source to destination

Quantity

User Manual

1 2 3 4

1

2

3

4

User Changed as : BG_WM_GG_I01Min /max Screen

Page 21: Automation on Non -feeders

LBI - Microsoft

Manual Receiving Process from CEVA To BA supermarket

Receiving process through digitalizing data and material traceability

Improve Phase – before/ after ID M A C

# Key Factor Description (Muda's )Eliminati

on

Improvement strategy

Solution Status Completion date

Owner

1Receiving materials

with errors ( Differences ) From

CEVA

The orders got from CEVA For non

feeders are not quantified

properly and we face the mismatch

in qty inside BA Supermarket

Inventory loss

To Avoid Loss of materials while receiving we planned to activate

an traceability method to track all the boxes and reels

Local user tool provided to track the

materials and store the

records in a Local server

Completed 17/08/2016 Dhivagar

Rathinam / Mahesh

After

CEVA SECURITY

Bfo Operator

Before

Operator verifying Document Chopped By material flow guy

No document Stored or recordedTraceability of abnormality is under risk

No digitalization of Receiving record

Storing

Scanning the Transfer order P,Q,Z To the Local tool LID Printed LID Pasted in the packs

Stored to racks Report of Receiving

Microsoft Excel Worksheet