PROJECT
APS TASK DESCRIPTION
NO. MODULE(S)
CURRENT (As of Nov-18)
1 SYSTEM MAINTENANCE
a) Business Partner Master Data i) Update Customer/Supplier/Subcon Info
b) Item Master Data ii) Update Item Name & relevant details
c) Warehouse/Location iii) Update TCM/Subcon Warehouse & Location
d) Bill of Materials (BOM) iv) Update BOM for each item
2 GENERAL MAINTENANCE
a) User/Admin i) Register/Deactivate users
b) Shift Info ii) Shift set up (working hours)
c) Machine List iii) Register/Delete machine & update item
involve for the specific machine
d) Process Info iv) Register/Update process names & type (In-
house/Subcon): For Process Cycle Time & Job
Planning purpose
e) Process Cycle Time v) Setting up involved processes for each item,
Subcon Location & cycle time
f) Doc. No. vi) Serial No. format eg. Customer DO No. (DO-
201805-0001)
g) Miscellaneous - Other maintenance
3 SALES ORDER
a) Registration i) Register customer's purchase order
b) Listing i) View details, Edit or Delete PO.
c) Auto Purchase Order (to Subcon) i) Non-existing
c) Sales Forecast i) Key in Sales Forecast data for each item
4 PLANNING
a) Casting SO/Forecast Review (DDR) - i) Non-existing
Production Planning
b) Planning & Scheduling i) Forward planning with auto select of machine
& production start date recommendation.
ii) Planning strategy is Made-to-order.
c) Machine Capacity i) Selected range of month for Machine Capacity
(Planned & Actual), Production estimation,
schedule & actual running
5 TOOLING
a) Tooling Registration i) Register & update Tooling details
ii) Links to Process Cycle Time
6 JOB TRACKING
a) Job Tracking i) Raw Material > Raw Part (Cast) > 2nd Process>
FG Trackings
7 QA JUDGMENT (IPQC)
a) Casting Output Only i) QA Judgment: Approve/Re-sorting Request
8 SUBCON MODULE
a) Work Order Generation i) Not following 3C's procedure (business
process)
b) DO Receiving from Subcon i) Non-existing (Refer Job Tracking)
c) TCM Return/Transfer (Casting) i) Similar Function in BOM & IVN. (Refer
Issue>Internal Transfer)
d) Subcon Purchase Return (BOM & IVN.) i) Non-existing for Subcon Return (WIP)
e) Subcon Issue Note (BOM & IVN.) i) Non-existing for issuing Packing Material
f) Packing Material Receiving (BOM & i) Non-existing for receiving Packing Material
IVN.)
9 BOM & INVENTORY (current APS)
a) BOM > BOM list: Planner can review Raw Material
Stock Level before Job Planning
b) Inventory > Inventory List in every location of the
Warehouse including Subcon
c) Receive > Receive item from External (Supplier etc.)
d) Issue > To issue WIP, external & internal transfer
e) Return > Raw Material & FG Return from Jobs, Return
from External(Customer)
f) Delivery > Sell to customer
g) Stock Modify > Modification of stock qty
h) Stock Take > Cut off time & Inventory day: Physical book
balance
i) Stock Movement > Reporting stock movement/Traceability
10 RAW MATERIAL
a) Receiving i) Raw Material receiving using the "Receive"
Sub-Module in BOM & INV.
b) Request i) Request function is to request raw material for
the specific Job No. (in Job Tracking)
c) Issue i) Issue raw material for specific amount of the
Job & need to return material from the Job
d) Request Return i) Non-existing for Request Return
e) Material Return i) Raw Material must be return (in system) after
Job done
11 REPORT
a) Raw Material i) Raw Material (ingot) Detail
ii) Raw Material Transaction Detail
b) Production Report i) Casting
- Casting Detail Report
- Casting Summary Report
ii) Machining
- Machining Detail Report
- Machining Summary Report
c) Subcon i) Subcon Work Order Report (Detail)
ii) Subcon Receiving Report
iii) Subcon Purchase Return (Detail)
iv) Subcon Outstanding Work Order
v) Subcon Stock Card
vi) Location Status Report
vii) Packing Material Report
viii) Packing Material Location Report
d) Customer i) DO Transaction Report
ii) DO Item Transaction Report
iii) Outstanding PO Report
iv) Outstanding PO Report (Detail)
v) Customer PR
vi) Customer GR
APS TASK DESCRIPTION
FINE TUNE/MODIFICATION
GOAL
i) Update Customer/Supplier/Subcon Info - Remove unused functions
ii) Update Item Name & relevant details - Add function to indicate "Discon" & customer's
item.
iii) Update TCM/Subcon Warehouse & Location - Store to update TCM Warehouse/Location
iv) Update BOM for each item - Planner to update BOM for each item
i) Register/Deactivate users
ii) Shift set up (production hours): MC Setup
iii) Register/Delete machine & update item involve for - Process Involved:
the specific machine
iv) Update process code & names (common/package by - Machine & Labour Cost to be discuss further
Subcon): For Process Cycle Time & Auto PO purpose
v) Setting up involved processes for each item, dedicated - Expected Output is according to Tooling No.
Subcon & involved Tooling
vi) TBC- To set as current 3C format eg. DO135882
- Other maintenance - User's Authorization
i) Register customer's purchase order (Indicate Additional - Remove unused functions.
PO)
i) View details, Edit or Delete PO - Remove unused functions.
i) Auto-Generate, View & Edit PO to Subcon (PO Ref: - Filteration by Item Group (Pedal, Brakearch,
Customer PO + 20% of Total PO to compensate NC) Fishing etc.)
ii) PO Summary Review & Email to Subcon
i) Key in Sales Forecast data for each item
i) Summary of PO Qty, O/B FG & WIP, Cast & Sort, Scrap,
FC Qty & Final Stock Balance
ii) Planner's Summary Stock Review before Production
planning & scheduling
i) Daily Load Machine Plan (Casting Planning only):
Made-to-stock
ii) Prompt for maximum 6 model change per day
iii) Automated reporting of actual daily output & Mould
No. used (linked Output Prod. Daily Record)
i) Estimates MC capacity for every 6 months with
reference of past history and PO forecast.
i) Register Tooling & Auto-update status (tool life etc.) - Cavity No., Part Material, Part Weight, Runner
Weight, Tonnage
ii) Links to Process Cycle Time for Casting tooling no. - Tool life reporting: Total shots produced for
monthly and annually summary.
i) 3C Dept.: *Production - Raw Material > Raw Part
*Store - Raw Part > 2nd Process > FG
- Separates Job Tracking into Production Module &
Subcon Module
ii) Casting Output: Produces Lot Card w/ ID & go through
Casting IPQC
- Return to Store only after QC Approved. Re-sorting
request is not allowed to return Store.
- After Re-sorting & Approved, need to update Sorting
Out Report. Scrap Request shall be done and
Management Approval is required.
iii) Machining Output: Also Produces Lot Card w/ ID & go
through QC
- Lot ID acts as DO for Machining & need to clear WO at
the same time
- Clearing WO to declare the correct Machining inventory
& stock movement
i) QA Judgment: Approve/Re-sorting Request & To re-
approve Lot w/ necessary details
i) WO Generation from Casting Lot ID
ii) WO Generation from Subcon DO (Also generate WO
for Special Receiving.)
- Special Receiving: Recv DO as usual + Recv same DO.
but w/ remark "WO Finish" - Improvement on this
process flow.
i) Recv DO from Subcon: Recv. Multiple WO in one DO
but no mixing item.
- Also receive DO w/out WO from Local Casting.
ii) Special Receiving: Receive DO w/ extra qty of the item.
(WO not enough. Prob:Loss/Gain qty)
iii) Receiving Scrap Part (Approved Scrap by TCM): Item
mixed is allowed in one document.
- From a) Subcon & b) Casting/Machining
iv) Cancel/Uncancel DO Receiving
i) Receive Return from Subcon (regarding
Resorting/Rework Request) - MUST ATTACH ORIGINAL
LOT ID NO AS REFERENCE.
ii) Issue Transfer to Production (Casting) for
Resorting/Rework request - MUST ATTACH ORIGINAL
LOT ID NO AS REFERENCE.
iii) Production Issue Return to Store after
Resorting/Rework done (Remark: Resorting/Rework)
- This transaction in the system shall not affecting Sort
Result in Planner's DDR
i) Issue Purchase Return to Subcon (NC parts)
- W/ & W/out Work Order
i) Issue packing material to Subcon
i) Receive packing material from external
(Customers/Suppliers/Subcon)
> To use Raw Material Consumption in Casting for
Shimano Report
> Inventory List for items in every Location w/ status of
FG/WIP/PENDING
> Receive Raw Material from Supplier & PM from
Subcon/Customer
> To issue PM & use to replace UBS to issue out SAMPLE
(UBS is not monitored well)
> Goods Return & Purchase Return from Customer (Must
also receive PM)
> Sell to customer (Must also include PM)
> Modification of stock qty (TBC)
> Cut off time & Inventory day: Not only Parts but also
PM (1 Lot: Parts + Packing Material) (TBC)
> Reporting: Stock movement/Traceability/Stock Card for
every Subcon
i) Raw Material receiving. (refer BOM & INV. - Receiving)
i) Request by PIC in Production Department: State the
estimated amount of ingot
i) Issue ingot by batch after PIC Store checked system for
the FIFO Melt No.
i) If Production needs to return ingot, PIC need to
request before returning.
i) Material returned list (Returned material must remark
the Melt No.)
i) Raw Material (ingot) Detail
ii) Raw Material Transaction Detail
iii) Raw Material Data (BOM x Pcs) - Opening Balance &
Forecast
iv) Raw Material Daily Usage Monitoring: Detailed
summary monthly
i) Casting
- Casting Detail Report
- Casting Summary Report
ii) Machining
- Machining Detail Report
- Machining Summary Report
iii) Daily Die Casting Machine Performance with graph
- Data obtained from Production Daily Output Record
- Graphs (by Shift): M/C cycle time, efficiency, casting
shot, low speed NC, sorting NC
i) Subcon Work Order Report (Detail)
ii) Subcon Receiving Report
iii) Subcon Purchase Return (Detail)
iv) Subcon Outstanding Work Order
v) Subcon Stock Card
vi) Location Status Report
vii) Packing Material Report
viii) Packing Material Location Report
i) DO Transaction Report
ii) DO Item Transaction Report
iii) Outstanding PO Report
iv) Outstanding PO Report (Detail)
v) Customer PR
vi) Customer GR
OBJECTIVE/REASON(S) DEPT. STATUS
- Customer & Vendors database
- Part Name database
On-going
database
updates by
- Warehouse database TCM (3C
Data)
- BOM database
- User database
- Casting Planning
- Casting Planning and Output (restriction for
output name) Planner
- Auto PO to Subcon On-going
QC & Store database
updates by
TCM (3C
Data)
- Auto PO, available mould for Models QC, Store &
Planner
- Auto PO & DDR Planner
Store
- To view & make ammendment on customer PO
Store
- To view & make ammendment for Subcon PO
Store
- Forecast order for Casting planning & SOT Planner
- Data calculation by system for Casting Planning
reference
- PO qty, FG, WIP, Cast, Sort, Scrap, Forecast
- Planning & Scheduling for production
Planner
- Daily Model Change (schedule transition)
- Auto updates of Casting actual output in
Machine Plan
- To monitor machine utilization: Management
discussion for Production Planning
- Tool life monitoring
QC/Mould
Maint.
Production
QC
QC
Store:
Receiving
Store
Store
Project Gantt Chart
Phase I: In-house (Planning, Production & QA Department)
No. Module Task Description
1 System Maintenance
- Business Partner Master Data * - Update Customer/Subcon/Supplier
- Item Master Data * - Update New/Discon Item
- Warehouse/Location * - Update Warehouse/Location
- Bill of Materials (BOM) * - Update BOM for new items
2 General Maintenance
- User/Admin (Registration) - Register new Users (Store & Other Dept.)
- Machine List * - Update involved items for Casting Machine
- Process Info * - Update process info for item (common/package)
- Process Cycle Time * - Update Process involved/Dedicated Subcon/Tooling
3 Sales Order
- Registration * - Register Customer PO
- Listing * - To view/edit customer PO
- Sales Forecast * - Key in Customer PO forecast
4 Planning & Scheduling
- Stock Level Summary (DDR) - To review stock level before planning for Job
- Planning & Scheduling - Plan Job
- Daily Model Change - Replan Jobs if more than 6 model changes per day
6 Production Daily Output Record
- Daily Casting output record - Key in Casting output daily (By shift: Day & Night)
7 Job Tracking
- Casting output with Lot ID - Key in output with Lot ID
- Wait approval from QA - Return to Store if Approved, Re-sort & wait re-approval
8 QAQC
- Quality judgment - To Approve/Request Re-sort Casting Lot
artment) Plan Actual
Apr-19 May-19 Jun-19
PIC Status
WK1 WK2 WK3 WK4 WK5 WK1 WK2 WK3 WK4 WK5 WK1 WK2 WK3 WK4
Prepared by:
Jun-19
WK5
Prepared by:
