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Plan Order Management (Malay)

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Submitted By najibmyn
Words 1871
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CARA LAMA
Kanban Processing

3

Part Preparation

1

-Ordering data source
-Kanban scaan & sort
~32x/day(including OT)
-Send data to e-SIMS every time scan Send/transmit

2

-Data of kanban scan is store at s-SIMS database for one shift
-At the end of each shift ordering group will do ABUNKA for ordering
-Order via e-SIMS
-PML/PDIO based on vendors/TPL order cycle

Vendor

A

-Ordering data source
-Kanban scaan & sort
~32x/day(including OT)
-Send data to e-SIMS every time scan TPL

4

Storage

5

-Storage and supply
-Store part at PC rack
~Attach kanban to parts for supply -Received part and PML/PDIO
-Key-in PDIO/PML for receiving

B

6
Supply

-Ordering data source
-Kanban scaan & sort
~32x/day(including OT)
-Send data to e-SIMS every time scan Kanban function:
1-As a tool for supply activity
2-As a tool for ordering activity
3-As a tool inventory control activity

a)Assembly (A) shop
b)Body (W) shop
c)Engine (K) shop
-supply parts to line/shop
`32x/day(including OT)

CARA BARU
Kanban Processing

Receiving

3
1

-Ordering data source
-Calculation base on MPP(1 shift production plan)
-Adjustment stock base on production achievement previous shift

Send/transmit
-Data base on 1 shift requirement(calculation data)
-Ordering group will do
ANBUNka for ordering
-Order via e-SIMS
-PML/PDIO based on vendors/TPL order cycle

2

Part Preparation
Vendor
-Vendor received PDIO by ESIMS
`Print PDIO
`Send parts with PDIO

TPL
-TPLr received PML by E-SIMS
`Print PML
`Send parts with PML
Kanban function:
1-As a tool for supply activity
2-As a tool inventory control activity

A

Receiving
-Received part and PML/PDIO
-Key-in PDIO/PML for receiving

4

5
Storage
-Storage and supply
-Store part at PC rack
~Attach kanban to parts for supply B
Supply
a)Assembly (A) shop
b)Body (W) shop
c)Engine (K) shop
-supply parts to line/shop
`32x/day(including OT

6

KENAPA MEMILIH SISTEM PLAN ORDER?

Vendor rungut order lebih dari sepatutnya

Kanban hilang order tiada incoming

Kanban kurang dari jumlah sebenar order tidak cukup

Vendor rungut order tidak seimbang

Kanban lewat keluarkan order tiada untuk esok

Kenapa kanban scan banyak ,order jadi banyak,sedangkan penggunaan part sedikit sahaja?

Kanban function:

Plan Order function:

1-As a tool for supply activity
2-As a tool for ordering activity
3-As a tool inventory control activity

1-As a tool for ordering activity

Calculate Plan
Order

Upload MPP

Confirm
Calculation

Latest
MPP

1
Achievement

2

Submit
Calculation

3

Yes
Rebalancing?

Adjustment

Confirm
Adjustment

Confirm
Adjustment

Stock take/DPT

No

Data transfer to BL2 interface Submit Abunka
& Approve

5

4

Flow Plan Order

6

Order

PCD

ORDERING

7

STOCK
CONTROL

STORE/LINE

Apa itu Plan Order System?
Plan order system ialah satu cara bagaimana untuk membuat order atau membentuk cara order dengan mengimbangi part dengan jumlah pengeluaran dan keadaan semasa didalam pengeluaran
Bagaimana cara plan order beroperasi?
Plan order beroperasi berdasarkan jumlah Plan volume dari MPP (Monthly
Production Planing) yang ditetapkan oleh PCD (Production Control Department)
Contoh MPP (Excel)
Plan Volume (MPP excel)

Contoh MPP (Esims)
Plan Volume (MPP upload)

Bagaimana cara plan order mengimbangi order dengan pengeluaran sekiranya Plan
Volume tidak sama dengan Actual Volume?
Cara mengimbang order tersebut dengan pengeluaran sekiranya plan volume tidak mencapai target ialah dengan order untuk keesokan harinya ditolak dengan jumlah lebihan unit(volume)untuk order yang sebelumnya.
Contoh order :

Achievement
Jumlah order shift sebelum esok = 151 unit
231 unit
Kenapa Jumlah order hanya 151 unit sedangkan esok plan 181 unit?
Baki order 151 unit adalah disebabkan Plan order mengimbangi jumlah part untuk esok dengan mengambil kira baki unit yang tidak capai target pada shift sebelumnya sebanyak 30 unit lebihan.
Plan production
Esok 181 unit

Plan shift sebelum
261 unit

Formula :- D = ( B - C )
E=A-D
Main Calculation
A

B

C

D

E

MPP volume

Previous Shift
Plan

Previous Shift
Achievement

Balance Unit
(B±C)

Balance Unit To
Order

181 unit

261 unit

231 unit

30 unit

151 unit

Balance unit = Prev Shift Plan - Prev shift Achievement
Balance unit to order = MPP volume – Balance unit
Sasaran pengeluaran
Jumlah untuk order (MPP Volume)=181 unit
Baki unit yang masih ada
Baki unit/Stock in hand = 30 unit
Jumlah yang diperlukan
Baki unit untuk order = 181 - 30 = 151 unit #

Formula :- D = ( B - C )

&

E=A-D

A

B

C

D

E

MPP volume

Previous Shift
Plan

Previous Shift
Achievement

Balance Unit
(B±C)

Balance Unit To
Order

5 unit

6 unit

4 unit

2 unit

3 unit

Contoh :- balance unit = ( Prev shift plan – Prev shift ach )
Balance unit to order = MPP volume – Balance unit

&

A

B

C

D

E

MPP volume

Previous Shift
Plan

Previous Shift
Achievement

Balance Unit
(B±C)

Balance Unit To
Order

1 unit (kuning)

2 unit (kuning)

1 unit (kuning)

1 unit (kuning)

1 unit (merah)

2 unit (merah)

2 unit (merah)

1 unit (merah)

1 unit (merah)

1 unit (Biru)

1 unit (Biru)

1 unit (Biru)

1 unit (Biru)

1 unit (hijau)

1 unit (hijau)

1 unit (hijau)

Total 5 unit

Total 6 unit

Total 4 unit

1 unit (hijau)
Total 2 unit

Total 3 unit

Ruang DPT & Stock
Control/Adjustment
Round down & Up
Cumulative
Balance to order x
Qty/packing

1-OCT

2-OCT

2-OCT

3-OCT

3-OCT

Night Shift

Day Shift

Night Shift

Day Shift

Night Shift

Order Date

Tomorrow MPP

Production date Plan order guide

Previous
Achievement

Plan Order
Calculation

Previous
Achievement

Plan Order
Calculation

MPP 200 unit

Main calculation

ANBUNKA

Tomorrow MPP

MPP 200unit

Details calculation
Achievement
190 unit

Reduction stocks

Delivery/Incoming
190 unit

Balance body
10unit

3 shift to reduce
Stock overflow

1

2

3

1-OCT

2-OCT

2-OCT

3-OCT

3-OCT

Night Shift

Day Shift

Night Shift

Day Shift

Night Shift

Order Date

Tomorrow MPP

Production date Previous
Achievement

excess

Plan Order
Calculation

10unit(balance)

190unit (MPPbalance)

190unit
(achievement)

10unit(balance)

1

2

3

3 Sebab Part

MISSING

Tidak
Seimbang

BOM II ACCURACY

REJECT

PPC Department

BOM II ACCURACY

BOM II update & maintain data berdasarkan part list dari PPC o Kemugkinan part list usage/car & variant usage adalah salah. o Kebarangkalian tersalah update dari PPC dan BOMII juga ada.

Apakah sebarang tanda-tanda dari masalah ini?
Terdapat tanda-tanda ditunjukkan didalam masalah ini
 Part akan menjadi shortage sekiranya usage/variant tidak di update dengan betul
 Part akan menjadi overflow sekiranya usage/variant tidak di update dengan betul
 Vendor akan memberi maklum balas sekiranya ordering over order & less order
Bagaimana Plan Order System menghadapi masalah ini?
Line/Store/ordering akan maklumkan masalah ini dan meminta
BOMII membuat pengesahan dan pembetulan dengan PPC

Apakah yang dikaitkan dengan Missing?
Missing ialah part yang sudah order dan sepatutnya cukup tetapi tiada atau hilang kejadian ini seringkali dikaitkan dengan
MISSING
kecurian,kecurian seringkali berlaku kepada part tertentu
Antara kretiria part missing ialah : Part mahal (hot item) yang mendapat sambutan hangat dari pihak luar yang membeli dari individu tertentu yang mencuri/mengelurakan part secara haram dari store/line  Part yang senang disorok dan dibawa keluar seperti part kecil
 Membuat tranksaksi haram seperti membuat order kepada vendor tetapi hanya receive dan chop
PDIO/PML kosong tanpa meghanghantar part
Bagaimana Plan Order System menghadapi masalah ini?
Part akan menjadi shortage/critical dan part selalu ada additional order,items tersebut akan ditempatkan di Kandang(tempat yg sentiasa dikawal selia oleh pekerja)tetapi cara ini terhad kepada kecurian yang berlaku di store sahaja.Sekiranya berterusan EMC group akan membawa masalah untuk dibincangkan dalam PSM (Part
Security Meeting) dan akan diputuskan kepada jalan penyelesaian.

REJECT

Part Reject ialah part yang telah rosak atau tidak mengikut piawaian yang telah ditetapkan oleh perodua.
Apakah yang menyebabkan part reject?
 Part terjatuh
 Part Basah atau kotor
 Part yang tidak mengikut spesifikasi dan tidak mengikut standart yang telah ditetapkan
 Part yang mempunyai defect samada calar dan sebagainya. Apakah kesan part reject kepada production dan logistik?
 Part menjadi kurang untuk supply pada production line
 Boleh menyebabkan berlaku downtime sekiranya kuantiti yang reject tinggi
Bagaimana Plan Order System menghadapi masalah ini?
 Tindakan sementara ialah dengan membuat shortage order sekiranya part urgent untuk support line sementara menunggu Qi group membuat pemeriksaan kualiti
 Line atau store mengisi borang DPT (Defect Part Ticket) sebagai tanda pemberitahuan dan rekod kepada logistik/ordering
 Proses pengantian dilakukan (Adjustment DPT)sekiranya defect tersebut berpunca dari logistik/store/line(handling problem)
 Sekiranya Defect /reject berpunca dari Vendor pengantian atau replacement part di buat oleh vendor dengan kandar segera sebagai pengantian kepada part yang reject.

SIAPA YANG TERLIBAT & APA TUJUANYA?
Department/section/PIC yang terlibat
1-Data Part berdasarkan Bom2 update 2-Data MPP daripada PCD
3-Data Achievement daripada PCD
4-Pengesahan data order daripada ordering group

1-Dapatkan D-man data dari pihak Store(Over
Flow part)
2-Buat Check sheet Pengiraan
3-Melakukan Adjustment pada part tertentu
4-Pengesahan Adjustment daripada ordering group Mula

Plan order calculation Plan order
Adjustment

1-Ordering Submit Plan order
2-Diproses oleh system sepenuhnya
Plan order
Anbunka

1-Approved order yg telah dibuat
2-Memastikan order/delivery pada hari/masa yang sepatutnya Plan order incoming/delivery Tamat

Tujuan/Matlamat
1-Memastikan semua data di update dengan betul
2-Memastikan Order berdasarkan dari Plan yang sebenar 3-Mengawal Lebihan dan pengurangan pengeluaran
4-Memastikan Order yang dibuat mengikut Pengiraan sebenar 1-Melihat keadaan Stock untuk pemantauan)
2-Menetapkan Standart tertentu dalam pengiraan
3-Membuat Rebalancing part tertentu
4-Memastikan semua Adjustment dibuat dengan betul 1-Menetapkan order mengikut standart
2-Menyeragamkan (Heijunka)order kepada
TPL/Vendor mengikut cycle/trip untuk delivery

1-Supaya vendor dapat melihat dan membuat persiapan penghantaran
2-Memastikan vendor menghantar mengikut tarikh/trip/masa yang sepatutnya

1 -Pilih 3 fungsi utama kanban :i.
Untuk aktiviti supply ii. Untuk aktiviti ordering iii. Untuk kawalan inventory iv. Untuk aktiviti receiving

A.
B.
C.
D.

Semua di atas i,ii &iv i,ii & iii i & ii

2 - Yang manakah fungsi Plan order:i.
Untuk aktiviti supply ii. Untuk aktiviti ordering iii. Untuk kawalan inventory iv. Untuk aktiviti receiving
A.
B.
C.
D.

Semua di atas i,ii &iv i,ii & iii ii & iii

3 - Department manakah yang menentukan MPP (Monthly Production Planing) untuk Plan order?
A. Logistik
B. PCD
C. ISTD
D. PPC

4 - Pilih 3 sebab Plan order part tidak seimbang dan mengalami masalah :i.
BomII accuracy ii. Over load iii. Reject iv. Missing
A.
B.
C.
D.

Semua di atas i,ii &iv i,iii& iv ii & iii

5 – Daripada manakah data Achievement diambil untuk Plan order assy?
A.
B.
C.
D.

PBS
Line on Assy
Line off Body
Line off Assy

6 – Penyataan manakah yang BETUL tentang Plan order assy?

A.
B.
C.
D.

Plan order assy hanya order mengikut MPP sahaja.
BomII memainkan peranan penting didalam update setiap part
Plan order dibuat dan diproses sepenuhnya oleh system/esims
Shortage order dibuat untuk mengurangkan over flow part di store

7 – Kenapakah Plan order digunakan sebagai satu sistem order?
A.
B.
C.
D.

Mengurangkan kesalahah pengunaan kanban oleh perkerja semasa proses order
Plan order satu sistem yang menjamin tidak akan ada overflow part
Plan order dibuat dan diproses sepenuhnya oleh system/esims
Plan order digunakan kerana untuk mengantikan sistem kanban yang lama

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