|
|
  
Conversion to new Manufacturing Information System
|
|
BACKGROUND
A small Fiber Optic operation was acquired by
Tycoelectronics, a large multinational
company, because of its cutting edge technology and
development of new products.
The newly acquired facility had been mostly doing
research and development work and did not have a consistent
manufacturing data system. Tycoelectronics on the other hand had an established ERP
system.
|
CHALLENGE
|
The Fiber Optic facility had 8,000 part numbers which needed to be
converted
into Tycoelectronic's existing ERP system in 2 months. This would allow
Tycoelectronics to: 1) Estimate the cost of the product based on its labor and
material cost and 2) Use the routing information to schedule work orders
through the work stations
The major challenges in this implementation were:
- The incomplete or non existing documentation
in the fiber optic company had of its
products. Most of the production had been done with a research and
innovation mind set, not that of a ISO standardized manufacturing
facility.
- The limited time available to obtain the required information for
the 8,000 part numbers
|
|
|
MY
SOLUTION
-
Developed
categorization system for all part numbers
-
Standardized
the product families and types to allow mass conversion instead of
manual part number basis conversion
-
Clearly
identified the information required by the ERP software (PN,
Routing, Bill of Material, time study information)
-
Created
a plan with the most efficient way to obtain the information and
strategized
the best way to proceed when the information was unavailable (i.e.
time studies, creating flow charts, defining work stations,
determining equipment capacity, etc)
-
Led a
a multi functional team to research the necessary information
|
MEASURABLE ACCOMPLISHMENTS
| All of the Fiber
Optic's manufacturing data was incorporated into Tycoelectonics ERP
system in 2 months. The cost accuracy was increased. |
| Part Categorization. 10 mayor
product families were identified. The categories were based on research
done using the existing documentation, informational sessions with the
engineer and creation of flowcharts. |
Product Families |
 |
Product Types within a Product
Family Type
I, Type II and Type III |
Each product family consisted of several types of
product which contained approximately one hundred part numbers. This aided the standardization of the
management of the data.
|
|
Work Station Definition. In order to create the
correct workflow for each product type, the work stations needed to be
defined. Each work station was defined and clearly marked on the
production floor and its capacity was determined in labor hours .
|
Work Stations and Routings
|
| Routing Information. Once the stations were determined. The
work flow of each product type was determined. Time studies were
performed . |
|
