automation on non -feeders
TRANSCRIPT
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
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
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
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
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
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
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
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
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
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
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
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
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
LBI - Microsoft
Brain storming Idea Through Picture flow ID M A C
Process Plan in BA Supermarket for non-Feeder Materials and system flow
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
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
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
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
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
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
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