Order
Production plan
Stock Break-up
250000 200000 150000
64536 45378 25678 32104 49850 19980 28990 53245 15467 24568 19347 19370 31290 27456 51789 34678 21568 51000 37890 27846 42789 18890 31024 22780 32227 36789 21090 20347 44890 22457 19789
834
Total Inventory: unit/10,000 sec
-15%
978
1100 1000 900 800 700 600 500
280 54 150 17
45
149
RM Auxiliary materials Fuels Packaging materials Low value depleting materials WIP FP
Producing
Order
Production plan
EJENDALS PRODUCTION SYSTEM -DATA COLLECTION PLAN
Air freight
• Manufacturing process
WIP
Semi-finished
FG inventory
Stock Breakup
Statistical the stock
52350
98750 17680 23440
RM(Stock+on road) WIP Semi-finished FG inventory
Inventory Structure
FP Stock
Warehouse
Producing
DOH （day on house） = Stock Qty / Daily consumption Qty future 3 month
Order Production plan
The Inventory Quality Ratio(IQR)
The ratio of the active inventory dollars to total inventory dollars. In a theoretically perfect situation(i.e. With no excess, slow moving or obsolete inventories) the IQR would be 100%
• Manufacturing process
RM order5 issue
MU(Machine utilization rate)(1) RM
reception Inspection
Warehouse
RM stock
Formula： Qualified produced Qty/ Qty under theoretical Takt time*100%
100% 80% 60% 40% 20% 0%
Goa l Ja n Feb Ma r Apr Ma y J un J ul Aug Sep Oc t Nov De c
over 4 m onth 2-4 m onth W ithin 2 m onth
EJENDALS PRODUCTION SYSTEM -DATA COLLECTION PLAN
Remarks： Index evaluate running efficiency of production line
Payment Shipping FP Stock
RM/accessory on line
Warehouse
Producing
Order
Production plan
EJENDALS PRODUCTION SYSTEM -DATA COLLECTION PLAN
RM order3 issue RM FP turnover rate days Inventory Inspection reception Warehouse RM stock
Formula： 365 days FP turnover days= FP turnover rate Remarks： Payment Shipping FP Stock Warehouse Inventory FP Turnover days is the index to measure and assess the management of FP turnover status.
reception
Inspection
Warehouse
RM stock
Definition： E&O Over stock RM or products E：excess O：obsolete
Payment
RM/accessory on line
90 day<DOH<180day
Shipping
DOH>180day
Order RM/accessory on line
Producing
Production plan
Stock turnover rate
Stock consists of the whole value chain. Including stock/on the way/placed RM, WIP, FP, nondirect materials, FP on the way, FP in the distribution center, etc…
Benchmark：The Average Of Top 10% company
• • Inventory Turnover>2.0 Inventory decrease(5 years) - 35%
EJENDALS PRODUCTION SYSTEM -DATA COLLECTION PLAN
• Stock process
EJENDALS PRODUCTION SYSTEM -DATA COLLECTION PLAN
• Manufacturing process
RM order7 issue
OTD(onRM time delivery) Performance
reception Inspection
Warehouse
Benchmark from 1st quarter of1999 NA automobile industry:
Operating type Auto-assembly Semi-auto Manual assembly
Running efficiency 75-80% 80-90% 90-100%
• Manufacturing process
RM order6 issue
MU(Machine utilization rate((2) RM
reception Inspection
Warehouse
RM stock
Formula： （Available time－Machine fail time－ stop time from other factors /(Available time-stop time from other factors）*100%
RM/accessory on line
Producing
Order
Production plan
Unit: days
40 35 30 25 20 15 10 5 0 Jan
Turnover days
Analysis of FP turnover days
35 29 34 36
32 31
35
33 32
Formula： （sales cost*12 ）/ [（last month stock value + this month stock value）/2] Remarks： Payment Shipping FP Stock Warehouse Inventory Turnover is the comprehensive index to measure and assess the management of purchasing, production, sales management control.
33
28
Feb
Mar
Apr
Maj
Jun
Jul
Aug
Sep
Okt
Nov
35
28
29
34
31
32
36
35
33
32
33
EJENDALS PRODUCTION SYSTEM -DATA COLLECTION PLAN
• Manufacturing process
RM order4 issue
E&O cash RM ratio
RM stock
Formula： Actually delivered order/Confirmed delivery order *100% Remarks： Index to measure delivery
Payment Shipping FP Stock Warehouse
RM/accessory on line
-11%
182
311
-10%
85 9 47 111 11 46 75
400 300 200 100 0
others
-63%
204
2017
2016
EJENDALS PRODUCTION SYSTEM -DATA COLLECTION PLAN