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Material management   furniture making
 

Material management furniture making

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    Material management   furniture making Material management furniture making Presentation Transcript

    • 1APO TES Bangladesh Furniture Manufacturing Organization chart: Manufacturing Operation Chief Executive Operation Manager Factory Manager Production Manager Material Manger Maintenance & Engineering Research & Design Production Planning & Control QC, Tally Sample, Jig & Tools maker Tooling Tester, verifier QC, Inventory
    • 2APO TES Bangladesh Furniture Manufacturing Material management Function - Collect, analize and dessiminate information about material utilisation - Preparing the required materials - Determine the current stock level & its value - Ensure the materials is safe in keeping / storage
    • 3APO TES Bangladesh Furniture Manufacturing Materials controller Head of department, business owners Managers Executives / officers Supervisors Clerks  Organisation chart  Duties and responsibility
    • 4APO TES Bangladesh Furniture Manufacturing Requirement to become material controller Have knowledge about the materials under their supervision Given authority as material controller Have full responsibility of the goods under his care Has facilities to safe keeping the goods Have good knowledge about material management Document: stock book, inventory card etc.
    • 5APO TES Bangladesh Furniture Manufacturing Requirement to become material controller (cont.) Material management:  Planning the requirement  Purchasing  Receiving  Storage  Maintenence  Inventory  Releasing for processing  Disposing Membuat, melapor dan menyimpan rekod:  jenis bahan  Kuantiti  nilai
    • 6APO TES Bangladesh Furniture Manufacturing Requirement to become material controller (cont.) Material tendency to wear, damage, faulty & depreciate Mixing recipe Compatibility of materials to product manufactured Rate of utilisation
    • 7APO TES Bangladesh Furniture Manufacturing Materials properties Physical properties:  Type  Size  Grade  Density, chemical content etc.  Quality  Quantity  Value of materials  Material uses Mechanical properties:  Maintenance  Storage
    • 8APO TES Bangladesh Furniture Manufacturing Documentation Material specifications: name, model, physical properties Quantity: utilization rate – daily, weekly, monthly Suppliers: name, address, telephone, products supplied, terms and prices Purchasing document: L.O. (purchase order), delivery notes (D.O.), invoices
    • 9APO TES Bangladesh Furniture Manufacturing Documentations (cont.) Receiving: goods received notes  Name  Model  Grade, quality (refer to specifications)  Quantity Maintenance  Mechanical  Preventive Inventory  Quantity  Quality Production  Material request form - Stock card
    • 10APO TES Bangladesh Furniture Manufacturing Raw material management Unit: Kg., liter, ton, pieces, unit, packing, rolls, drums etc. Safe keeping and safety of materials Reports to superior officers & frequency Not leaking information to competitors Applying system: Location, storage methods, replenish Knowing stock levels and utilization rate
    • 11APO TES Bangladesh Furniture Manufacturing Responsibility of Material Controllers 1. Material inspection:  Before delivery (at suppliers warehouse); 2nd party audit  Ability of suppliers: to supply on time, delivery  Right information in documentations: purchasing, delivery notes, invoice  Quality supplied according to specifications  Quality is checked  Recording the classification changes (if any & allowed)
    • 12APO TES Bangladesh Furniture Manufacturing Responsibility of material controllers 2. Rejects materials which doesn’t meet specifications  Materials used to make the goods  Materials quality  Quantity  Expiry date  Non approve buyers / black listed  Disapprove brand and model
    • 13APO TES Bangladesh Furniture Manufacturing Responsibility of material controllers 3. Storing the materials:  Material classifications: type & physical properties  Safety levels; material depreciation, dangerous items  Able to determine current stocks and additional items  Taggings on materials, packages  Recording
    • 14APO TES Bangladesh Furniture Manufacturing Responsibility of material controllers 4. Conduct maintenance  Materials inspection  Ensure the materials is in good condition and able to function properly  Conduct maintenance appropriatly, i.e. change the packaging, change the tag, initiate the chemical reactions (glue / finishing materials), eliminate saturated components, oiling, block the undesired chemical reactions  Separate the expired & unfunctional items
    • 15APO TES Bangladesh Furniture Manufacturing Responsibility of material controllers 5. Implementing inventory / audit  Count the quantity  Compare the inventory and stock card figure  Search the cause of difference, if any  Justify the quantity differences  Ensure the right quantity  Inventory / stock reports  Stock values
    • 16APO TES Bangladesh Furniture Manufacturing Responsibility of material controllers 6. Giving out the materials  Who can receive the materials  Approval in writing  Have needs & according to production schedule  Preparing the required materials, refer to specifications  Exact quantity  Documentation: Material request forms,
    • 17APO TES Bangladesh Furniture Manufacturing Factory management and manufacturing facillities Raw materials Machines and manufacturing facilities Building and compound Vehicles
    • 18APO TES Bangladesh Furniture Manufacturing Materials classification: physical properties 1. Main raw materials: timber & panel items 2. Processing materials: sand paper & glue 3. Dangerous materials: thinner, oil, finishings 4. Hardware: screw, hinges, connectors, accsessories 5. Packaging: fabrics, boxes, foam, strap etc. 6. Workers: first-aid, mask, earplug, glove, measuring tape, caliper 7. Machines: tooling and spare parts
    • 19APO TES Bangladesh Furniture Manufacturing Storage places for raw materials Materials is not store at one place Grouped to physical properties Place to be used, processing place Safety structure
    • 20APO TES Bangladesh Furniture Manufacturing Materials: Green sawn timber Air-dried sawn timber; anisotropic Grade: 1. Prime 2. Select 3. Standard 4. Sound 5. Serviceable 6. Utility Stacking: a. Species b. Size c. Sticker Cement flooring, even Covered
    • 21APO TES Bangladesh Furniture Manufacturing Timber calculations Sawn timber 1 cu. ft. = 0.0283186 M3 1 ton = 50cu.ft.= 1.41584 M3 1 M3 = 0.7063 ton sample: 2.25” x 3.5” x 8’, 125 pieces Calculate in tonage? (l x t x p)/(12 x 12 x 50) x pcs = 2.25 x 3.5 x 8 /(7200)x 125 = 1.09375 ton
    • 22APO TES Bangladesh Furniture Manufacturing Calculation M3 t” x l” x p” x pcs. = ft.3 1728 ft.3 = M3 35.31 Notes: 1728 = 12 x 12 x 12 35.31 = 50 1.41584 Example: 1.75” x 3.75” x 48” ada 312 pcs. 1.75 x 3.75 x 48 x 312 = 56.8749 ft3 1728 56.8749 ft.3 =1.610733 M3 35.31 56.8749 ft.3 = 1.1375 ton 50
    • 23APO TES Bangladesh Furniture Manufacturing Materials: Kiln-dried timber Moisture content: _ % MC Equilibrium moisture content, EMC: 12 – 13 % Stacking: closed stack (no stickers) Bundled: same specie & sizes, same lengthwise, applied wax/paint at ends, wraped in plastics, same distance of support, 4’ Covered area, cemented, even & have walls
    • 24APO TES Bangladesh Furniture Manufacturing Materials: dressed timber Cut and planned to final size Desired MC% Bundled: same specie, same size & wrapped Storage area: covered, cemented, even & in building Far from cold / heat: climate changes caused timber to defects Ukuran: M3
    • 25APO TES Bangladesh Furniture Manufacturing
    • 26APO TES Bangladesh Furniture Manufacturing
    • 27APO TES Bangladesh Furniture Manufacturing
    • 28APO TES Bangladesh Furniture Manufacturing Bahan: mouldings Kayu berprofil Contoh: frame, splint, skirting, jamb etc. Bundled: sama spesis, sama profil, sama saiz, dibungkus plastik, ikat. Susun dalam crate Ukuran: ft. run, mr
    • 29APO TES Bangladesh Furniture Manufacturing Bahan: komponen perabot Contoh: turnings, kaki, tops dll. Berbagai bentuk, saiz dan warna Finished & unfinished Disusun, dibungkus & diletak ditempat teduh Jangan simpan > 4 bulan (kayu); akan hilang ketepatan saiz, profil
    • 30APO TES Bangladesh Furniture Manufacturing Bahan: papan panel Papan lapis Binaan: lapisan venir berperekat disusun ira berselang seli dalam bilangan ganjil Perekat: urea formaldehyde (MR – moisture resistance) & phenol formaldehyde (WBP – water boiling proof) Gred: face – back; AA, BB, CC Value added: laminated face – tego film Susunan: jenis perekat, gred, saiz, dibungkus, kawasan teduh Kayu penggalas: sama saiz, jarak 2’, 6” dari hujung
    • 31APO TES Bangladesh Furniture Manufacturing Bahan: papan panel lain Fiberboard (MDF, HDF) Chipboard Softboard Particleboard - Binaan: habuk/serbuk/serpai kayu, berbagai saiz, digaul dengan perekat - Ukuran: ketumpatan, saiz (4’x8’,6’x8’,3’x6’) - Gred: mengikut pelepasan formaldehyde; E0, E1, E2, E3 - Susunan: mengikut jenis, saiz, gred, kawasan teduh, dibungkus plastik - Kayu pengalas: sama saiz, jarak 2’
    • 32APO TES Bangladesh Furniture Manufacturing Bahan: pelapik muka Formica, Maica Aica High pressure laminate (HPL); Post forming, soft forming - Backing: kertas, plastik, venir - Perekat: contact glue - Susunan: mengikut jenis, saiz, dibungkus - Suhu: terkawal; < 24°C
    • 33APO TES Bangladesh Furniture Manufacturing Bahan: kertas pasir Jenis: granit, kaca, silica Gred: paling kasar (00), halus (480) Backing: kertas, kain, plastik Perekat: contact glue, protein Kegunaan: mempelas, kemasiapan Bentuk: mengikut mesin; sheet, wide belt, disc, long belt Simpanan: bilik hawa panas (30°C -35°C; guna lampu 15 watt) Susunan: kepingan (disusun), gulungan (digantung)
    • 34APO TES Bangladesh Furniture Manufacturing Bahan: perekat Water-based, oil-based PVAC, urea formaldehyde, contact glue, glukosa, hot melt glue, protein, super glue etc. Hardener, retarder Shelve life: sebelum campur hardener Pot life: selepas campur hardener Standard guna: kelikatan (viscosity) Bekas: bersih, tiada benda asing, bekas khas, kuantiti standard i.e. 20kg, 18L Bilik: suhu sejuk < 20°C; superglue (peti sejuk)
    • 35APO TES Bangladesh Furniture Manufacturing Bahan: minyak Kenderaan: petrol, diesel, cylinder, coolant, transmission Mesin: grease, hydraulic Gred: SAE (kelikatan) Ukuran: liter Bekas khas: kedap udara, tiada benda asing, jauh dari bangunan awam Bilik sejuk (< 18°C), bawah tanah
    • 36APO TES Bangladesh Furniture Manufacturing Bahan: kemasiapan Nitro cellulose (NC), acid catalyzed (AC), poly urethane (PU), cat, varnish, minyak Ukuran kekuatan: resin content, solid content Kualiti: hardness, durability, kilauan Bahan lebur: thinner, air; retarder Shelf life; pot life Mudah terbakar, terpeluap Bekas khas: kedap udara, jauh dari bangunan awam Suhu simpanan: sejuk (< 28°C)
    • 37APO TES Bangladesh Furniture Manufacturing Bahan: pengikat Skru, paku, bolt & nut, staples, minifix Spesifikasi: panjang, diameter, bentuk kepala, bahagian pemutar, bentuk hujung, saduran, warna Rosak: karat, berubah warna Bungkus: plastik, spesifikasi, kuantiti mudah Bekas: kotak Stor utama
    • 38APO TES Bangladesh Furniture Manufacturing Bahan: penyambung Hinges, connector, catches Spesifikasi: tempat kegunaan, saiz, model #, warna Rosak: karat, gagal berfungsi dengan elok Bungkus: mengikut model, plastik, kuantiti mudah Bekas: kotak Stor utama
    • 39APO TES Bangladesh Furniture Manufacturing Bahan: aksessori perabot Tombol laci/pintu, kunci, drawer slide, toe kick, stopper Spesifikasi: kegunaan, saiz, warna, model Rosak: lusuh, karat, gagal berfungsi Bungkus: mengikut model, kuantiti mudah Bekas: kotak Stor utama
    • 40APO TES Bangladesh Furniture Manufacturing Bahan: aksessori berasaskan plastik Screw caps, slides, adjuster, padding Spesifikasi: saiz, warna, model Bungkus: plastik, kuantiti mudah Suhu: kurang dari suhu bilik (< 28°C) Bekas: kotak Stor utama
    • 41APO TES Bangladesh Furniture Manufacturing Bahan: fabrik & kulit Kain Bahan: kapas, polyester, wool etc. Mengikut bentuk tenunan Spesifikasi: bahan asas, warna, lebar, ketahanan, model Bungkus: gulung (roll), baring, kayu / kodi Kulit Stor: kering, suhu > 28°C
    • 42APO TES Bangladesh Furniture Manufacturing Bahan: pembungkusan Kotak, PU foam, plastik wrapper, strap Assembly instruction sheet, write up Kotak di pipihkan, ikat Dibungkus, bahan tidak jadi lusuh Stor: kering, suhu > 32°C
    • 43APO TES Bangladesh Furniture Manufacturing Bahan: keselamatan pekerja Dusk mask, ear plug, gloves, safety shoes Pakaian seragam, apron Dibungkus plastik diikat dalam kuantiti mudah Stor utama, kering
    • 44APO TES Bangladesh Furniture Manufacturing Bahan: alatan pengukuran Measuring tapes, veneer caliper, gauges, moisture meter Simpan kering Stor utama
    • 45APO TES Bangladesh Furniture Manufacturing Bahan: tools Alatan tangan: screw driver, pliers, spanner, tukul besi, wrenches Simpan: kuantiti mudah Stor utama
    • 46APO TES Bangladesh Furniture Manufacturing Bahan: mesin tooling Knives blade, profile knives, circular saw, band saw, drill bits, router bits Disusun atas rak, kotak panel Mudah karat Senggaraan: sapu minyak Stor mesin
    • 47APO TES Bangladesh Furniture Manufacturing Bahan: senggaraan Kunci: peti kunci Tangga Alatan elektrik: mentol, volt meter, wire Stor sengaraan
    • 48APO TES Bangladesh Furniture Manufacturing Mesin kecil Jig saw, hand router, hand trimmer, drill, screw driver dll.: elektrik & air powered Diberi nombor rujukan unik bagi setiap satu Nama pengguna dicatitkan mengikut tarikh & waktu Disimpan dalam setor alat Dipasang mata & diuji sebelum dan selepas dikeluarkan dari setor
    • 49APO TES Bangladesh Furniture Manufacturing Peralatan semburan Kemasiapan: spray gun, hos, pump, tangki dll. Perekatan: spray gun, hos dll. Dibersihkan selepas digunakan Diberi nombor rujukan unik Disimpan di setor semburan Rekodkan nama pengguna
    • 50APO TES Bangladesh Furniture Manufacturing Mesin tetap X-cut saw, rip saw, moulder, panel saw, router, drill, sander, air compressor etc. Bekalan elektrik betul & pendawaian selamat Alat keselamatan & tooling terkawal Terlindung dari cuaca yang melampau Mesin diikat dilantai rata dengan kukuh Diberi nombor rujukan unik Ada jadual senggaraan Nama operator / senggara
    • 51APO TES Bangladesh Furniture Manufacturing Peralatan kilang Dust extractor, silo, piping, spray booth, conveyor, hoist, work bench, perabot dll. Ditempatkan / melalui kawasan yang selamat. Ditanda dengan kod warna Diperiksa / dibersihkan secara berjadual
    • 52APO TES Bangladesh Furniture Manufacturing Kenderaan & handling equipment Pallet truck, forklift, roller conveyor, lori, van, kereta dll. Disimpan ditempat yang dikhaskan Disenggara mengikut jadual Operator yang dibenarkan sahaja
    • 53APO TES Bangladesh Furniture Manufacturing Bangunan & kawasan Bangunan, pondok, tempat letak kenderaan, pagar, parit, tangki kumbahan, taman, pintu, tingkap, tangga dll. Tiada yang tersumbat, kotor, tidak terjaga Tiada tempat pembiakan Menugaskan anggota khusus untuk menjaga kawasan dan bangunan Harta benda selamat & terkawal
    • 54APO TES Bangladesh Furniture Manufacturing TQM: Concept - TPM 5 S’s of Good Housekeeping  1) Seiri - disposal of unnecessary things  2) Seiton - make sure that things are in the current place  3) Seiso - clean up, sweep & polish  4) Seiketsu - keep things clean - repeat 1,2 & 3  5) Shitsuke - discipline
    • 55APO TES Bangladesh Furniture Manufacturing TQM: Concept - TPM 5 C’s of Good Housekeeping 1) Clean out - determine what is necessary & unnecessary & dispose of the latter 2) Configure - provide a convenient, safe & orderly place for everything & keep it there 3) Clean & check - monitor the condition of the area during cleaning 4) Conformity - develop the habit of routinely maintaining cleanliness 5) Custom & practice - train people in the disciplines of the 5C’s
    • 56APO TES Bangladesh Furniture Manufacturing 5 S (Bahasa Malaysia) Sisih Susun Sapu Selia / Seragam Sentiasa amal
    • 57APO TES Bangladesh Furniture Manufacturing TQM: Concept - TPM Ciri organisasi TPM  Menyatukan bahagian senggaraan & pengeluaran  Pasukan kecil terdiri dari operator / penyenggara  Latihan menjadikan ‘operators feel like owners’  Tabiat baik membentuk: Pembersihan menjadi pemeriksaan Pembersihan menampakan kepincangan Kepincangan diperbaiki Pembaikan berterusan untuk peralatan dan suasana
    • 58APO TES Bangladesh Furniture Manufacturing TQM: Konsep - TPM Step 1 (what does the company require?) Step 2 (is everything in order?) Step 3 (clean up) Step 4 (keep clean) Step 5 (educate people about the rules)
    • 59APO TES Bangladesh Furniture Manufacturing TQM: Konsep - TPM Sasaran TPM  Memaksimakan keberkesanan peralatan  Membentuk sistem PM disepanjang hayat peralatan tersebut  Dilaksanakan di semua bahagian  Melibatkan semua pekerja  Mempromosikan PM melalui pengurusan motivasi – aktiviti kumpulan kecil
    • 60APO TES Bangladesh Furniture Manufacturing TQM: Konsep - TPM 5 aktiviti pembangunan TPM: 1) Menghapuskan 6 punca kerugian utama (slide berikut) untuk memanjang hayat peralatan. 2) Program senggaraan yang bebas 3) Program senggaraan terancang 4) Meningkatkan kemahiran anggota operasi & senggaraan 5) Program pengurusan peralatan asas
    • 61APO TES Bangladesh Furniture Manufacturing TQM: Konsep - TPM Fokus TPM keatas 6 punca utama kerugian peralatan 1) Peralatan tidak berfungsi 2) Set-up & adjustment time 3) idling & minor stoppages 4) Mengurankan kelajuan 5) Kecacatan proses 6) Mengurangkan hasil perolehan Kumpulan kecil yang bebas fokus kepada 6 punca utama kerugian
    • 62APO TES Bangladesh Furniture Manufacturing Kita tangguhkan dulu.