ctr workflow project

By ProcessesBy Job FunctionBy Location

Quote to PO Process PO to Traveller

WO Traveller to Floor

Kitting Traveller to Floor

Floor to Final Inspection

Traveller Close Out

Shipping to Invoice-Stock

CTR, Inc.

Stakeholders (Customer)

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“Quote to PO” Procedure

“Quote to PO” Procedure

Review Part List Problems?Info Received by

email

Ask for Quote by email w/ Part List

Customer received Quote

Give Part List to Document Control

No

Yes?

Part List received at Document Control

Start creating and breaking down Part

List

Place labels and kit-lists into the M Drive

Inform PM

PM informedInform Assistant

Quoter about Verified Kit Lists

Assistant Quoter enters M drive and opens verified Kit

Lists

Info PM of formula inputting Kit-List

Doc Control produces:1.Part Labels2. Manufactured Kit-List3. Purchased Kit-List

M Drive

Apply pricing formulas to Kit-List

w/ Quote Sheet

PM reviews formulated Kit-List

Review part prices to ensure profit margin.

5 Methods

Enter prices into formulated Kit-List

Final Quote Price

produced by formulas

Final Quote Price reviewed and then

emailed to Customer

Quote Accepted?

YesContact PM for renegotiation

No

Contact Customer for clarification

PO to Traveller Process Begins

Quote to PO ProcessBegins

PM begins renegotiation w/

customer

Email part list with either an ADCN or

DCN

Quote to PO ProcessBegins

Doc Control CCed on

email

Double Check:kit-lists verified by other Doc Control

M Drive

M Drive M Drive

Quote Tab

Quote Tab

Kit Lists Tab & Labels Tab

ADCN: Advanced Document Change NoticeDCN: Document Change Notice

Part List

Part List

Revision Change?

No

Yes

Begin Revision Change Procedure

Problems?

Yes

No

Customer contacted.


Internal or external?

External

Talk to previous personnel that held

documentation Internal

Customer gives clarification

Problems?




documentation

Yes

No

External

Internal

Review Kit Lists and Tabs

Customer contacted.


Problems?




documentation

Yes

External

Internal

Review Kit Lists and Tabs

Customer contacted.


OrOr

Customer contacted.


M Drive

Doc Control CCed on

email

CTR, Inc.

Stakeholders (Customer)

VP

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“PO to Traveller/s” Procedure

“PO to Traveller/s” Procedure

PO to Traveller Process Begins

PO Created

Receive Customer’s PO

Send PO to CTR

Begin Review Process.

(PO Revision check)

Print PO and supporting documents

Give PO and supporting

documents to Doc Control

Doc Control receives

PO and supporting documents.

Validate VP Revision Change Decision

Does the Revision Change?

Begin Revision Correction

Process

Yes

NoBegin

Acknowledgement Process

Give PO & Acknowledgment to

VP

VP receives PO & Acknowledgment

Begin Risk Assessment

Process

Pass Risk Assessment?

Inform customer of situation

No

Client Receives Information

Client makes changes

Risk Assessment Signed

Yes

Give PO, Risk Assessment, and Acknowledgment to

Doc Control

Receive PO, Risk Assessment, and

Acknowledgment from VP

Review documents and apply corrections

Original placed File Cabinet.

(Open Cabinet)

Original

Use copy to create WO Traveller and

print drawingsCopy

Traveller Creation

Process BeginsTraveller to Floor

M Drive

Client PO

Is this a “Pull to Stock” PO?

“Direct Shipping” Procedures(Pull from Stock)

Yes Take to the Floor

Make 1 Copy

Supporting Document:Email of Quote Agreement

No

AKA Direct Shipping

Reply

Is the package complete?

Yes

Delivery Date Criteria

Reason for Check: Verify signature Verify Stamp of Approval Verify delivery dates

Original or copy?

M Drive

No

VP CCed on email

Doc Control CCed on

email

Replied to Quote(if any)

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nWO Traveller to Floor

Traveller to FloorWhat type of Travellers?

Give WO Traveller to Planning

Stock: Build to Forecast&

Details & Assemblies

Give WO Traveller to PM

Kits(Kitting)

Planning receives WO Traveller

Review all WO Travellers

Estimate Routings1. General Costs2. Check Routings3. Verify BOM4. Verify Material5. Apply Back Date

Machining or Sheet Metal?

Machine Supervisor Receives WO

Traveller/s

Sheet Supervisor Receives WO

Traveller/s

Machining

Sheet Metal

Review WO Traveller/s

Review WO Traveller/s

Issues?

Issues?

Return to Planning

Yes

Return to Planning

Yes

Floor to Machine Processes

Floor to Metal Sheet Processes

No

No

Criteria Check? Pass

Reason for Check: Multi-Order Consolidation Rev Change Likelihood Resource Management Time to Delivery “Floor Flooding”

Fail

Return to Document Control

Internal or External?

External

WO Traveller/s place “On Hold”

Internal



Inprocess Inspection Complete

Inprocess Inspection Complete

Planning Approval

Planning Approval

CTR, Inc.D

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Kitting To Floor

PM receives WO Traveller

Panasonic Open PO List

Consolidated Kit Travellers

Same kit repeat in 90 days?

Yes

No

O/H Inventory? Sure

Inventory Check

No Sure

Check Bill of Materials (BOM)

Print BOM listConsolidated

Kits?No

Quantity X # of Kits on Print BOM list

Yes

Scrub and ReconcileBOM to build

(Build vs OH Inventory) Multi-Action

Give Traveller to Procurment

Procurment receives Traveller

Give BOM to Document Control

Doc Control receives Printed BOM

Printed BOM

Printed BOM

Modified-Printed BOM

PM’s Personal Inventory Checklist

Use notes and review for outside manufacture parts

Begin Purchasing of Outside Manufacturing

Parts

Begin Purchasing of Electronic and electric

Parts

WO Creation Processes for Details and

Assemblies

Review Modified-Printed BOM

PO created

CTR PO createdSpecial/new

Purchase Parts?No

Yes

Research special items and vendor sources

Regardless of type (Electronic, manufacturing, etc)

M Drive

Update Inventory items, detail drawings, and assemblies drawings

M Drive

Consolidates Travellers in multiples of 10.

Panasonic Open PO List

Check Panasonic Open PO LIst

Purchase Hardware List

Perform an Urgency Check

Urgent?

Job is need before the 2 weeks.

Criteria

Consolidated Travellers for the

Month

No

Inventory O/H? No

Create Purchase Hardware List to

Consolidate Needs

Hand Purchase Hardware List to

Shipping Supervisor

Shipping Supervisor receives Hardware

List


Shipping Supervisor assigns list to

shipping personnel

Inventory Checking Process

Yes

VP or QC Manager receives PO for

Signature

CTR PO

Give PO to VP for Signature

Give PO to VP

VP/QC signs PO

Shipping Supervisor receives ‘Urgent’

Request and Traveller

Shipping Supervisor assigns Urgent

request to shipping personnel

Procurement is notified and handed

the PHL.


PO for Outside Manufactured Parts

Update E2 based on Inventory

Results

CTR PO

PO for Electronic and Electric Parts

Pull Inventory from E2 Wait 2 Weeks

Release Kitting Travellers to the

Shipping

No

Multi-ActionFile Purchasing Hardware List

Purchase Hardware

Receiving Process

Signatures can also be performed by the Quality Manager


Traveller to Floor

Shipping to Invoice/Stock

Build to Stock Process


Multi-Action

Urgent?

Yes

CTR PO


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Floor to Final Inspection

Floor to Metal Sheet Processes

Material handler receives Traveller

Supervisor gives Traveller to Material

Handler

Is the material OH?

Report to SupervisorNo

Supervisor is notified

Gives material and traveller to next

Work Center

Material Procurement Process

Clock into E2

Yes

Clock out of E2

Is the material OH running low?

No XPick Material

X

Perform Operation

Gives parts/material and

traveller to next Work Center

Clock into E2 NoClock out of E2 X

Floor Personnel Receive Traveller

and Matertial/Parts

Material/Parts

Clock into E2 Clock out of E2Inform Floor Inspection

Begin OperationsSetup required? Yes

No

Inspection Pass?First Run Setup

BeginsYes

Review Traveller to determine next

routing operation

Parts

Floor Inspector Performs

Inspection

Inspection

Last routing operation in

Traveller?No

Punch OPS

Shear OPS

Deburr OPS

Select an Next Operation

Press Brake OPS

Milling OPS

Lathe OPS

Outside Processing OPS

Counter Sink OPS

Inprocessing Inspection OPS

Final Inspection

OPS

Setup OPS

Part Mark OPS

Joggle OPS

Touch Up OPS

Laser OPS

Sub Out OPS

Yes

Multi-ActionShipping to Invoice/

Stock

Traveller Close Out

Multi-Action

Is the Operation missing in Traveller?

No

Give Traveller to Planning

Yes

Control 1: Master Routing Changes

Planning receives Traveller

Review TravellerMaster Routing

Updating

Return to Floor Personnel

Part Shortage?

Supervisor/Expidter/PM receives information of

shortage

Traveller Shortage Process


Supervisor receives Shortage Traveller

Yes

Yes

Hold Traveller

Multi-Action

Has Shortage Traveller or Extra Pieces arrived?

No

Due to Scrap or Misplacement


Troubleshooting Process

Part Shortage?

No

Scrap Process

Scrap Process Scrap Process

Detail or Assembly Traveller?

Detail

Supervisor gives Traveller to

Assembly Personnel

Assembly

Assembly Personnel receives Traveller

Final Piece or for assembly?

Final Piece

Check Stock for Details

Begin Pre-Assembly Process

Multi-Action Assembly

INV Shelves

Ready for Assembly?

Yes

No


Troubleshooting Process

Yes

Stock OPS

Back Date OPS

Perform OperationClock into E2 Clock out of E2Begin Operations

Scrap Process

Part Mark OPS

Joggle OPS

Kitting OPS

Final Inspection OPS

Back Date OPS

Material/Parts

Material/Parts

Part Shortage?Last routing operation in

Traveller?No YNo

YSelect an Next

Operation

Yes

Select an Operation Is the Operation missing in Traveller?

No

Give Traveller to Planning

Yes

Detail or Assembly?

Detail

Return to Assembly Personnel

Assembly

Assembly

Multi-Action


Traveller Close Out


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Traveller Close Out

Traveller Close OutGive traveller to Procurement or

Document Control

Receives Finished Traveller

Review Process Begins

Certification Completed?

NoQuantity Produced Correct?

Yes Extra StockYesDoes Planning

need to be notified?

Inform Planning and give traveller

Yes

Planning informed and traveller

receivedReview Traveller

Master Routing

UpdatingYes

Routing Changes?

Speak with Supervisor

No

E2 Updating Process

YesE2 Close Out

Process

No

Separate Traveller and all

documentation to Close Cabinet

Return to Procurement and Document Control


No

Close out Cabinet

No


Review Traveller comments and

notes


Control 2: Master Routing Changes

QC/QA Manager receives Traveller

Review Certification Issues

Speak with QA/QC Manager

Material Certs or Hardware Certs

Certs Correction Process


Vendor Interactions on Certs

Quick Fix?Back-Tracking

AuditNo

Yes

Shear, Machining, and/or Kitting

Control _: Certificate Review

Control _: Paperwork Correction

CTR Inc

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Shipping to Invoice

Direct to Shipping

Shipping receives folder from VP.

Supervisor reviews folder/traveller.

They (Panasonic) call it “WIP Shortage”

Revision Check

Assign folder/traveller to

personnel for Picking

Picker receives folder/traveller

Revision Check Process

Fail

PassPlace parts in the

package box

Traceability Process:1. Record WO# for Manuf parts2. Record PO# for Purchase parts3. Label Box/es

Hand box and folder/traveller to supervisor for Review

Issues? NoSetup

Transportation Pickup

FEDEX

Air or Ground?

Is it passed 3:30pm?

Ground

Is it passed 4:30pm?

AirIssues that the

supervisor cannot fix?No

Inform VP in order to fill out FEDEX

informationNo

No

It is a Friday?Yes

It is a Friday?

Yes

Wait next day and begin process

No

No

Next Day Passes

Wait until upcoming Business Day

Yes

Yes

First Business Day Arrives

Transportation Arrives

Transportation Picks Ups Packages

“Direct Shipping” Procedures

(Pull from Stock)

Give PO and Acknowledgement folder to Shipping

Supervisor gives folder to Doc

Control

Yes

Doc Control receives folder from Shipping

Review Revision Change Checklist

Part List

Hand over to Panasonic’s Source

Inspectors

Yes

Panasonic’s Source Inspectors receive

packages

Panasonic’s Source Inspectors approve

Does it pass inspection?

Yes

Inspectors inform shipping supervisor

on deficiencies

No

Return package and folder to CTR

Packages return from Source

Inspectors on Receiving Shelves

Receiving Shelves

Supervisor reviews approved folders.

Green Dot of Approval

Air, Ground, or UPS

Place Left of Dock

Air

Place Center of Dock

Ground

Transportation Departs

Create Shiplist of Items shpped

Yes

Shiplist Excel Sheet

Give Panasonic and CTR MGMT Shiplist

Panasonic Procurement Team

Receives Shiplist

Place Right of DockUPSMGMT CCed

on email

Stace and Sy

TammyLisa BLisa H

Rev ChangeChecklist

Was it completed?

Create folder for new revision

and place it in cabinet

No

Search Cabinet for Folder

YesIs the folder

there?

Place folder in its proper

alphanumeric order Yes

Inform Shipping Supervisor

Part List

M Drive

Inform Shipping Supervisor

Create Duplicate Folder(labeled as duplicate)

No

Place it in cabinet

Size and Weight of Boxes are recorded

VP receives Transportation

Setup info.

Packing Slip creation

Shipping Supervisor receives packing slip

from VP

Supervisor reviews packing slip

Invoice

Customer receives Invoice

FEDEX

Packing Slip

VP notifies Shipping Supervisor and

hands packing slip

Copy of Packing Slip

Invoice

Copy ofInvoice

Panasonic Customer?

Hand folder and supporting

document to VP

VP receives folder and documentation

Packing Slip

Copy ofInvoice

Review folder and documentation

VP gives folder and documentation to

Doc Control

Doc Control receives folder from Shipping

Cabinet in Shipping Area

Cabinet in Shipping Area

Cabinet in Doc Control Area

Place folder in “Close’ cabinet

End

End

Panasonic Inspection Required?

No

Give Accounting the Invoice

VP sends invoice to Customer

Multi-Action Create Invoice

Accounting recieves the invoice

Invoice

A/R Process

End


Parts / Assemblies

Floor/Assembly Personnel stock the

parts and assemblies

INV Shelves


Release Kitting Travellers to the

Shipping

Pick the Parts & Assemblies

INV Shelves

Cheat Sheet

First Check:Find other personnel

to review work

Kit Lists Tab & Labels Tab

Issues? No

Yes

Shortage List:Last Minute Items

Rework or Kitt Shortage

Yes

Rework Procedures

Rework

Supervisor/Assistant supervisor Picks Parts

INV Shelves

CTR, Inc.D

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Begin Revision Change Procedure

Kit or Detail Change?

Detail

Compare “From” and “To” Review

Changes

Does it affect CTR?

Reason for Changes: Dimensional Changes Hole Pattern Changes Material Call Out Finishing Call Out Specification of Material Change Specification of Finish Change

(They affect CTR)Or

All of the Above, but for Non-CTR details(They don’t affect CTR)

Criteria

Notify Quality Control

Yes

Place all open orders associated with the revision on “On Hold”

QC received notification of

Revision Change

Part List Revision

No

M Drive

Update Revision information and

drawings

Is production affected by the

change?Yes

Rework, Salvage, or Scrap.

Floor production associated with all

those parts are stopped.

Begin Rework Procedures

Rework

?Salvage

Begin Scrap Procedures

Scrap

Notify PM

PM notified.

?

No

Revision Change Procedure Ends

Build revision cost estimate

Review the Revision Change w/ Rev Change

Checklist (ADCN/DCN)

Rev ChangeChecklist

?

Kit

ctr workflow project

Design