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Operation Diagnostic Review

By Jessica Murphy,2014-04-29 02:41
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Operation Diagnostic Review

    Merloni TermoSanitari

    Business

    Consulting

    Operation Diagnostic Review

    MTS BPCS Manufacturing Module Implementation

    September 22,1999

    Merloni TermoSanitari Phase III Operation Diagnostic Review Process One: Production Plan Maintenance

    No Steps Purpose Key Person Input Level of Time Output

    Automation 1. Sales forecast Provide reference Sales Rolling Manually Every Rolling

    to make the Coordinator Forecast maintain in Month Forecast Sheet

    production plan Sheet computer

    2. Considering the sales forecast Maintain the Planner Rolling Manually In the Production

    and the inventory situation, production plan of Forecast maintain in middle Forecast;

    maintain the Production the following few Sheet; Excel of each Production

    Forecast and the Production months and the Inventory month Schedule of

    Schedule of next month (with detailed production Situation next month

    detail information of each plan of the next Report;

    day) month Production

    Capacity

    3. Approve the production To control the Managing Production Manually Every Production

    forecast and the production process of making Director; Forecast; approve Month Forecast;

    schedule of next month production plan ManufacturiProduction Production

    ng Manager Schedule of Schedule of

    next month next month 4. If it is not approved, revise To ensure the Planner Production Manually Every Production

    the production forecast and correctness of the Forecast; revise Month Forecast;

    the production schedule production plan Production Production

    Schedule of Schedule of

    next month next month 5. If it is approved, pass the Provide production Planner Production Manually Every Production

    approved Production plan information to Schedule pass Month Schedule of

    Schedule to the related related next month

    persons and departments departments

    6. Keep the Production Forecast Keep the Planner Production Every Production Page 2 of 18

    Merloni TermoSanitari Phase III Operation Diagnostic Review No Steps Purpose Key Person Input Level of Time Output

    Automation

    in the production department production forecast Forecast Month Forecast

    as the reference

    Page 3 of 18

    Merloni TermoSanitari Phase III Operation Diagnostic Review Process Two-I: Shop Order Release and Print F.G

    No Steps Purpose Key Person Input Level of Time Output

    Automation 1. Run MRP 510 in BPCS based MRP running Planner Production Manually in Each

    on the Production Schedule Schedule BPCS Day 2. Explore MRP 600 in BPCS MRP Explosion Planner Manually in Each

    BPCS Day 3. Release plan orders Planned Order Planner Manually in Each

    release BPCS Day 4. Print the Shop Order Picking Provide picking list Planner Plan Order Print in the Each Shop Order

    List and Shop Order FG and F.G receipt form PowerbuildDay Picking List;

    Receipt Form er Shop Order

    F.G Receipt

    Form

    Page 4 of 18

    Merloni TermoSanitari Phase III Operation Diagnostic Review

    Process Two -II: Shop Order Release and Print S.F.G

    No Steps Purpose Key Input Level of Time Output

    Person Automation

    1. Shop Order Maintenance Input item number Planner Production Manually in Each Day Shop Order

    and the quantity of Schedule BPCS

    the production

    2. Shop Order Release and Release the shop Planner Shop Order Manually in Each Day Shop Order

    Print order for production BPCS

    3. Print the Shop Order Provide the raw Planner Shop Order Print in Each Day Shop Order

    Picking List and Shop material picking list Power-Picking List;

    Order FG Receipt Form and the finished builder Shop Order F.G

    goods receipt form Receipt Form

    for production

    Page 5 of 18

    Merloni TermoSanitari Phase III Operation Diagnostic Review Process Three: Normal Production

    No Steps Purpose Key Person Input Level of Time Output

    Automation 1. Production Supervisor pass the Shop For the Production Shop Manually Pass Shop

    Order Picking List to warehouse material Supervisor Order Order

    transfer Picking Picking

    List List 2. Inventory Transaction-“T” to transfer Transfer Warehouse Shop Manually do

    the raw material from 9A-Good to 9A-raw Supervisor Order inventory

    WIP according to the shop order material to Picking transaction in

    picking list; WIP List BPCS

    location to

    facilitate

    production

    3. Production Process Production Production Each Day

    Department

    4. Production Declaration Inventory Receive the Production Manually do Each Day

    Transaction “M” to receive the F.G to finished Supervisor inventory

    9A-WIP and decrease the R.M in 9A-goods and transaction in

    WIP decrease the BPCS

    raw

    material

    5. Pass the F.G to do inspection; Production

    Fill the scraped and damaged sum of Supervisor

    raw material in the Shop Order F.G

    Receipt Form

    6. Quality inspection Quality Each Day

    inspection

    7. If the F.G is qualified after inspection, Transfer the Warehouse Manually do Each Day

    Page 6 of 18

    Merloni TermoSanitari Phase III Operation Diagnostic Review No Steps Purpose Key Person Input Level of Time Output

    Automation

    warehouse clerk do the inventory finished Supervisor inventory

    transaction “T” to transfer F.G from goods to transaction in

    9A-WIP to 9C-GOOD; good BPCS

    location

    8. If the F.G is not qualified after Transfer the Warehouse Manually do Each Day

    inspection, warehouse clerk do the finished Supervisor inventory

    inventory transaction “T” to transfer goods to transaction in

    F.G from 9A-WIP to 9C-IN to do the inspection BPCS

    second inspection;

    9. Second-time inspection Quality

    inspection

    10. If the F.G still can not pass the second Transfer the Warehouse Manually do Each Day

    inspection, warehouse clerk do finished Clerk inventory

    inventory transaction ”T” to transfer goods to the transaction in

    F.G from 9C-IN to 9K-DG damaged BPCS

    location

    11. Warehouse clerk do the inventory Transfer the Warehouse Manually do Each Day

    transaction “T” to transfer the scraped damaged Clerk inventory

    R.M from 9A-WIP to 9K-DG or RS raw transaction in

    according to the scraped situation in material BPCS

    Shop Order F.G Receipt Form

    12. After each kind of production is Return raw Production After one

    finished each month, production material Supervisor kind of

    department listed the R.M to be from WIP to product

    returned and return the R.M in WIP to warehouse finish

    warehouse. production 13. Warehouse Clerk check the quantity Warehouse Warehouse Manually do

    and do inventory transaction “T” to receive the Clerk inventory

    Page 7 of 18

    Merloni TermoSanitari Phase III Operation Diagnostic Review No Steps Purpose Key Person Input Level of Time Output

    Automation

    transfer the R.M to 9A-GOOD or DG raw transaction in

    material BPCS

    returned

    14. Shop Order Close Planner

    Page 8 of 18

    Merloni TermoSanitari Phase III Operation Diagnostic Review Process Four: Production Cycle Counting

    No Steps Purpose Key Person Input Level of Time Output

    Automation 1. Monthly production supervisor print out Print out Production Each Month

    the cycle counting work sheet to prepare the cycle Supervisor

    cycle counting in 9A-WIP location counting

    work sheet

    to prepare

    the cycle

    counting

    2. Cycle Counting in WIP location Cycle Production Manually count Each Month

    counting Department

    3. Cycle Counting post in BPCS Cycle Production Manually do Each Month

    counting Supervisor cycle counting

    post post in BPCS 4. Print out the Cycle Counting Variance Print out Production Manually print Each Month

    report the cycle Supervisor out the report in

    counting BPCS

    variance

    report

    5. Pass the Cycle Counting Variance report Approve Production Each Month

    to the manufacturing department the cycle Supervisor

    manager to approve counting

    variance

    report

    6. If the manager approve the variance Cycle Production Manually do the Each Month

    report, the production supervisor do counting Supervisor inventory

    inventory transaction “Y02” to adjust adjustment transaction in

    inventory stock BPCS

    Page 9 of 18

Merloni TermoSanitari Phase III Operation Diagnostic Review

Page 10 of 18

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