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1、BenjTSManufacturingMaterialsManagementManualThismanualexplainstheplanforsatisfyingFordMotorCompany9SMS-9000requirements.Thismanualisintendedtobeusedinseminarworkshops.Theformatandcontentcanbeusedtoassistcompaniesindevelopingtheirownmaterialsmanagementmanual.Ifthismanualisusedasatemplate“theuserneeds
2、tobeawarethatthismanualdoespurposelynotaddresssomeMS-9000requirements.Theresponsibilities,authoritiesandimerreIationsforthosethatmanageyperformandverifythematerialsmanagementsystemwillbeidentifiedthroughtheuseofproceduresandworkinstructions.Theactivitiestobeperformedwillidentifythemanagerwhowillesta
3、blishandimplementtherequiredprocedureforsupportingtheoperationsoftheMaterialPlanningandLOgiStiCS(MP&L).Themanufacturingsystemmanagementrepresentativeisresponsibleforfimplementing,maintaining,andensuringthatallpersonsinvolvedwiththematerialmanagementsystemunderstandtheobjectives,Benji9SManufacturingi
4、sdedicatedtoachieving100%ontimedelivery,everimprovingthemanufacturingcycletime(MCT)9inventoryturnsandsubcontractordeliveryperformance.Jobdescriptionsforallpersonsinvolvedinthematerialplanningandlogisticsfunctionsareavailableinthehumanresourcefiles.Themanufacturingsystemmanagementrepresentativeisresp
5、onsiblefor,providinganupdatedcontactlist(includingtopmanagement),tothecustomer.Customercontactswillbeavailableduringallcustomerworkinghours.TheAQPprocedure(100-ENGR-XX)includestheappropriateMP&Lpersonnel.TheseindividualsparticipateinandsignoffontheAQPprocess.TheAQPprocessevaluatesUseergonomicstoassu
6、reefficientemployeeoperationsinmaterialsmanagement.Keymeasurements,thatverifythesuitabilityandeffectivenessofthematerialsmanagementPrOCeSs,areincludedinBenji9SManIifacturingQOS.BenjVsManufacturingperformsannualself-assessmentsoftheQOSusingtheFordQOSAssessmentandRatingProcedure.RecordsoftheQOSreviews
7、andannualself-assessmentsaremaintained.BenjifSManufacturinghashousekeepingpracticesthatarecoveredwithallemployeesduringnewemployeeorientation.Thesepracticespromoteasafe,efficientworkenvironment.Housekeepingprocessauditstakeplaceweekly.Recordsareavailableinthemanufacturingsystemmanagementrepresentati
8、vefiles.4.2 MaterialsManagementSystemBenji9SManufacturinghasestablishedanddocumentedthismanagementmanualthatcoverstherequirementsofMS-9000.Themanual,relatedprocedures,workinstructionsandrecordswillbemaintainedtoensurethatthecustomerreceivestherightquantityrightproduct,attherighttime.Thismanualwillin
9、dexthematerialsmanagementsystemproceduresandworkinstructions.TherelatedprocedureswillsatisfytherequirementsofMS-9000.Placeacurrentmaterialflowdiagramforthefacilityinthislocationofthemanual.BenjifsManufacturingusesmotionstudiestooptimizethematerialflowthroughtheoperation.Themotionstudiesfocusonnon-va
10、lue-addedworkandtimedelays.Thesestudiesareincluded加thecontinuousimprovementeffortsoftheQOS.4.3 ContractReviewZCiistomerInterfaceAspartoftheContractReviewProcedure(100-SM-CR-XX)9Benji9sManufacturingidentifiespotentialdeliveryproblemsandcommunicatesthentothecustomerwhentheyareidentifiedduringthecontra
11、ctreviewactivities.Thecustomerisalsocontactedconcerningallerroneousinformationthatcanaffecttheabilitytomeetrequirements.Resolutionsonallunresolvedissuesarerequiredtobefoundanddocumentedpriortotheclosingofcontractnegotiations.Duringcontractreview,customerrequirementsconcerninganinteractiveinventoryma
12、terialsmanagementsystemsuchasDirectDataIJnk(DDL)isaddressed.Ifaninteractiveinventorysystemisused,dailyshortagesandnewmodellaunchrequirementsareaccuratelyansweredinaccordanceWithFordprocedures.Informationisavailabletothecustomerthroughouttheiroperatinghours.Theorderentryprocedure(orderentryIll-SM-OE-
13、XX)ensuresthatthemethodofcustomerapprovalisestablishedensurethatinitialshipmentsofnewmodelmaterialsarenotmadewithoutcustomerapproval.ThisprocedureisalsousedtoreconcilecumulativeshipquantitydisagreementswithcustomerinatimelymannerThetoolingmanagementprocedure(110-ENGR-TM-XX)requiresthatcustomerapprov
14、alisreceivedpriortodisposingorreworkingtooling.Electronicdatainterchange(EDI)systemthatinputsAIAGEDI830transactionsandEDI866sequencedshiprequirementsareaddressedaspartoftheadvancedqualityplanningprocedure.TheEDIinputentersdirectlyintotheschedulingsystem.Theschedulingsystemisorderdriven.Thescheduling
15、systemdoesallowtheoptionofbuildingtoaninventoryifrequiredby(hecustomerorthecustomersshorttermforecastingabilityhasproventobeuntrustworthy.Theseoptionsarecontrolledthroughtheuseoftheproductionschedulingprocedure(120-PC-PS-XX),Theschedulingsystemmaintainsparameters(subcontractorleadtimes,manufacturing
16、cycletimes,shippingtimes,andresourcerequirements)tocorrelatemanufacturingrequirementswiththecustomersshiprequirements.Thepurposeofthesystemistominimizetherequirementsforpremiumfreight.Thesystemautomaticallyperformscomparisonsofcapacityandthecustomerrequirementprojections,bypartduringtheorderentrypro
17、cess.Allfilesarebatchedandprocessedduringthefirstshifttolookattheentiresystemformaterialandprocessingconstraintsthatmightaffectdelivery.Thesystemhasplanningcapabilitiesforbothcontinuousanddiscreteprocesseswithalongtermplanninghorizonofsixmonths.Theproductionschedulingprocedureensuresthatproblems,whi
18、chmightaffectcapacity,arecommunicatedtothecustomer.Theprocedurealsoassuresthatsufficientmaterialsareavailabletocovercustomerordersduringbalance-out.ItWiIIguaranteethatpre-Job1partsareavailableinatimelymannertosupportchangeoverandlaunchrequirements.Theschedulingprocesscoordinatesbalance-outsandengine
19、eringchangestoschedulesinordertominimizeobsolescenceexposure.Functionalbuildmaterialmustalwaysbeavailableinatimelymannerforrunningchanges(whenrequested).Whennecessary,theschedulingprocesswillreleaseshipmentsofnewmodelservicepartspriortotheinitialshipmentofproduction.Theshippingconsolidationprocedure
20、(119-PC-SC-XX)providesthedisciplinesthatpreventunauthorizedover-shipmentstothecustomer.Thedocumentanddatacontrolprocedure(100-DDC-XX)isusetoensurethatdocumentsanddatarelatedtothematerialssystemarereviewedandapprovedbyappropriatepersonnelpriortoissue.Theprocedureupdatesamasterlisttoprecludetheuseofin
21、validand/orobsoletedocuments.Theprocedureensuresthat:* Issuesofdocumentareavailableatalllocationswhererequired.* Itivalidiobsoletedocumentsarepromptlyremovedfromallpointsofissue.* Obsoletedocumentsthatareretainedforrecordsaresuitableidentified.* Informationrequiredforreviewmustbeavailable.Forchanged
22、documentstheprocedureensuresthatthosejobfunctionsthatoriginallyissueddocumentsanddatarelatedtothematerialsystemmustreviewanychangespriortoissue.4.6PurchasingiSubcontractorManagementThepurchasedpartreleaseprocedure(100-PPR-XX)allowsforbothEDIandmanualreleasestosubcontractors.Releasestosubcontractorsv
23、iaEDIareavailableforthosesubcontractorswhohavecompatiblesystems.Thefrequencyoftransmissions(EDIandmanual)tosubcontractorsisconsistentforeachproductandthedocumentedleadtimes.Forcustomerproductsthatexhibitfrequentchangesinvolumerequirements(lowpredictability)theminimumtransmissionsaredaily.WhenASNtran
24、smissionsarenotreceived,theprocedureensuresaccuraterecordingandverificationofrecords.Emergencyrequirementsarecoordinatewithsubcontractors.SubcontractordeliveryperformanceisameasurementforBenjisManufacturingQOS.QOSsummariesonperformance(trendcharts,Paretochartsandverificationover-time-charts,correcti
25、veandpreventiveactions)areavailableforsubcontractordeliveryperformance.Thisprocessconsistentlyimprovessubcontractordeliveryperformanceovertime.Subcontractorsarerequiredbycontracttostrivefor/00%on-timedeliveryforallreleases,whichrespecttheirdefinedlead-times.Aspartofthereceivingmaterialprocedure(100-
26、RM-MH-XX),incomingproductisevaluatedtoverifyqualityofpackaging.Correctiveactionsarerequestedfromsubcontractorswhenpackagingproblemsareidentified.ProperpackagingstandardsarecoveredaspartoftheAQPprocedure.CorrectiveactionsareusedtoupdatetheAQPprocedureandpackagingstandardstopreventsimilarproblemsforfu
27、turepackagingstandards.Returnabledunnageisselectedwheneverpossible.Theprocedureincludesbar-codedreceivinginformationdirectlyintothematerialscontrolsystem.4.8 ProductIdentificationandTraceabilityThematerialpackagingworkinstructions(IXX-MI-XX)willensurethatallcontainersarelabeledtocustomerexpectations
28、.Thepackagingstandardswillensurethatshippinglabelsconformindustrystandardshippinglabels(AIAGstandardB-3fUSAfOdettestandardEurope).Whenrequired,speciallabelsforsometransportationroutingssuchasconsolidationwillbeused.Thebar-codeprintershavespecialinternalscannerstoensurereadabilityofbar-codeddata.Them
29、aterialmanagementsysteminterfaceswiththematerialpackagingworkinstructioninordertodirectspecialattentiontonewmodelpartshipmentstoensureproperlabelingtocustomerrequirements.Newmodelpartswillbeclearlylabeledtoensuresegregationfromcurrentmodelparts.Barcodingisusedtotrackallmaterialthroughouttheoperation
30、.Thisincludesincoming,inprocess,andshippingconsolidation.Thisguaranteesthatallquantitiesofmaterialsareaccountedforandtrackedthroughouttheprocess.Specialbarcodesareusedtoidentifyscrap,returnedproductandrejectedproduct.Thisensuresappropriateidentificationofallunusableordamagedmaterial.Allstorageareasa
31、reclearlymarked.Thebarcodingandmaterialmanagementsystemensurethatallmaterialrecordsmustbeupdatedbythecompletionofeachshift.4.9 ShippingThematerialmanagementprocessandbarcodingpracticeswillguaranteethattheappropriatefieldsoftheASNareaccurate.Shippingunitsareconsolidatedatshippingstagingarea.Thescanni
32、ngprocessforshippingtakesplaceatthislastpossiblepointintheshipmentprocess.TheprogrammingofthesystemwillguaranteethatanASNcannotbesentwithoutallfieldsentered.ASNsaretransmittedatthemomentthecarrierdepartstheshippingdock.Thetrafficandshippingprocedure(100-TS-MH-XX)ensuresthatoutgoingshipmentscomplywit
33、happlicablecustomsregulations.Thisprocessalsoprovidesanefficientmethodforgeneratingrequiredpaperwork.Shippingdocumentsarepreparedtocustomerstandards.4.10 ManufacturingFlexibility/InventoryManagementFlexibilityandresponsivenessoftheproductionprocesswillbemeasuredandimprovedthroughtheuseofQOS.Themeasu
34、rementwillbemanufacturingcycletime.BothVolumelmixflexibilityandproduct/changeoverflexibilityareincludedintheadvancedqualityplanningprocedure.TheAQPprocedureisimprovedcontinuouslytoimproveflexibilityforeachnewlaunch.InventoryturnsareaQOSmeasurement,whichensuresthattheyareoptimizedovertimeforrawmateri
35、als,purchasedparts,work-in-processandfinishedgoods.4.11 InspectionMeasuringandTestThecontrolsoftheshippingquantitymeasurementsystemsareincludedintheMeasurementControlProcedures(100-MC-QE-XX),Theprocedureguaranteescalibrationtoanaccuracyasdefinedbythecustomer.Theprocedurealsorequiresperiodiccalibrati
36、ontoarecognizedstandard.Theprocedurerequiresthatallmeasurementequipmentisclearlyidentifiedtoindicatethecalibrationstatus,4.14 CorrectiveandPreventiveActionBenjifsManufacturingusesaTeamProblemSolvingprocedure(100-TPS-XX)topreventdeliveryfailures.Thisprocedureassurestheeffectiveresolutionofsupplyprobl
37、emswithoutcostpenaltiestothecustomer.Theprocessrequiresthattheorganizationreactsimmediatelytoproblemsidentifiedbythecustomer.Theprocessidentifiesrootcause,correctiveactionandactionstopreventrecurrence.Theprocessalsodevelopsshort-termsolutionstoensurecustomersatisfactionduringemergencysituationssucha
38、scomputersystemfailures,telephonelineoutages.Theshort-termsolutionsareverifiedtoguaranteeeffectiveness.4.15 Handling,Storage,Packaging,Preservation&DeliveryMaterialHandlingprocedures(XXX-MH-MC-XX)areusedtoensurecontrolforallphasesofmaterialhandlingofproductandpackagingmaterials.Thesecontrolspreventd
39、amageofbothproductsandpackagingmaterials.Theprocessesalsoensurethatreturnablecontainersanddunnagearereturnedinatimelymannerandinanacceptablecondition.Authorizedreceiptanddispatchofmaterialintoandoutofstorageareasareusedtotrackmaterialthroughoutthemanufacturingprocess.Theauthorizedreceiptprocessisini
40、tiatedthroughtheuseofthebarcodeprocess.BenjifsManufacturingdoesnotuseexternalwarehousingorstoragefacilitiesThematerialmanagementsystemhasamonthlyprocessthatisusedtoverifyinformationinthereferencedatabase.TheEDIprocessensuresthataccuratepackagingdataforallpartsonreleaseisconfirmeditthecustomerfssyste
41、mbeforeashipmentismade.Theaccuracyofweight,quantityanddimensionaldatawillbeverifiedwiththecustomeronanannualbasis.Theshippingprocedurenotifiestheoutboundcarrierofshippingrequirementsinatimelymanner.Thecarriersareexpeditedthroughtheuseofappropriateequipmentsuchasbracingandairbagstoensurethatproductar
42、enotdamagedintransit.4.16 ControlofMaterialRecordsBenji9SManufacturingmaintainsandutilizesaccuraterecordsofin-process,finishedgoods,purchasedpartsandrawmaterialavailable.Theserecordsserveasabasisforthematerialsmanagementsystem.Thebarcodingprocessassuresrecordintegrityincludingcyclecounting.4.17 Inte
43、rnalMaterialAuditsInternalauditsaremanagedthroughtheuseofthequalitysystemInternalAuditingprocedure(100-IA-QE-XX)toassessthecapabilityofallimportantmaterialsmanagementprocesses.Recordsaremaintainedtoverifythatauditshavebeencarriedoutasscheduled.Personsindependentofthefunctionbeingauditedperformtheint
44、ernalaudits.4.18 TrainingBenjifsManufacturinghasaTrainingProcedure,whichproducesannualtrainingplanstoassurethatallpersonnelinvolvedwithmaterialplanning,andlogisticshavethepropertrainingeducationand/orexperience.TheTrainingProcedurerequiresthatverificationoftrainingeffectivenessforallpersonnelinvolvedwiththematerialplanningandlogistics.4.20StatisticalTechniquesStatisticaltechniquesareusedasappropriateinmaterialplanningandlogistics.Forecastanddemandmodelingareproceduresareusedtoidentifyoptimuminventorylevelsandcontroltheapplicationofstatisticaltechniques.
