PYMAC BASIC EDUCATION BOM MODULE Prepared by: PC div YEVN-18th April 2013 CONTENT BOM introduction Organization Structure SU code Item Number & Item key Concept of SU Manufacturing process & BOM Data Item Definition Item Class Item Status 10.Revision Notice and Effective date 11.Stock Location 12.Work Center 13.Load sum code 14.Operation/ work flow INTRODUCTION TO BOM MODULE WHAT IS BOM???  BOM : BILL of Material  Function of BOM module : Provide fundamental info about : Item Information, Product structure Location of Itiem in Plat form/ Stock point/ Work Center Supplier & User of each Itiem MRP information and Manufacturing Engineer Info [MAIN FUNCTION ] [ SUPPLEMENT FUNCTION ] OP BOM PP Bill Of Material (DE& ME info) Order Processing Production Plan I-0P MRP CP Material Requirements Planning Capacity Plan CC BOM provide fundamental for other modules IC Inventory Management Cost Control VICS PUR/IA Unit Cost Registration Oversea Purchase Vehicles Control Our goal: Ensure BOM accuracy rate 100% Title BOM Basic Education Sub Title ORGANIZATION STRUTURE YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div Title BOM Basic Education Sub Title S/U code YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div YEVN Standard Definition of S/U CODE & P/F CODE Customer Customer 7xxx 9140 9130 9150 ⑤IGN COIL ③ST MOTOR 9120 ④UNIT S/P S/P Ign coil Pouring ②STATOR Stator P/F P/F P001 MOTOR Stator Pouring Stator Manual Insert 9900 Coil 1xxx~ Armature Coil winding ⑥Non-Process 4xxx Unit Winding Winding MOTOR ①ROTOR SMT Stator 9110 ROTOR ROTOR Pulsar Armature Vendor Vendor Title BOM Basic Education Sub Title S/U code YEVN PYMAC -III YEVN-18 Total digits : th Apr 2013 Made by: PC div 0 □□□□ YEVN Standard Definition of S/U CODE Source of part In-House S/U 91xx 　　　 Comment xx = alpha-numeric (0,1,…9,a,b,…y) Manufacturing Vendor 99xx 1xxx 　 *except i,o,q,z 　 Example Plant : 91xx * If increase the factory, use 92xx … Non Process : 99xx Overseas Vendor : 1xxx~2xxx Same as above Purchasing Local Vendor : 3xxx ~ 4xxx 4xxx Vendor Purchasing 5xxx Same as above Vendor : 5xxx 7xxx Same as above Customer : 7xxx - Indirect , Others - Customer Title BOM Basic Education Sub Title S/U code SU_CODE YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div SU NAME 1000 YAMAHA MOTOR ELECTRONICS JAPAN 1001 YAMAHA MOTOR ELECTRONICS INDONESIA Oversea 1002 YAMAHA MOTOR ELECTRONICS TAIWAN vendors 1003 YAMAHA MOTOR COMMERCIAL TRADING (SHINGHAI) CO.,LTD 3001 KYOSHIN VIETNAM CO.,LTD 3002 ASTI ELECTRONICS CORP HCM 3003 DRACO PCB PUBLIC CO.,LTD 3004 ASTI ELECTRONICS HANOI CORP., 3005 KYOEI MANUFACTURING CO., LTD 5001 NAGOYA INDUSTRIAL EQIPMENT CO.,LTD 5002 LONG SON CO., LTD 5003 DUY HUNG IMC CO., LTD 5004 NITTO DENKO CO., LTD 5005 HA SON 9110 ROTOR ASSY 9120 STATOR ASSY 9130 STARTING MOTOR ASSY 9140 IGNITION COIL ASSY 9150 CDI UNIT ASSY 9900 NON PROCESS 7001 YAMAHA MOTOR VIET NAM 7002 PART CENTER YAMAHA MOTOR VIETNAM 7003 YAMAHA MOTOR ELECTRONICS THAILAN 7004 YAMAHA MOTOR ELECTRONICS TAIWAN 7005 YMAC Local vendors Indirect vendors In- house manufacturing Customer Title BOM Basic Education Sub Title YEVN PYMAC -III YEVN-18 PYMAC ITEM th Apr 2013 Made by: PC div 1.Item Number & 　 Item Master ( For Normal Parts) PYMAC-Ⅲ DE Item Number/ Item Master Example: Ordinary part No New-BASE (R&D) Part Number 5VT-H1450-01 OOO-OOOOO-OO Part No system is defined by YGK 10 digits Color Indication No.also defined by YGK 5VT-H1450-00-0080 Item Number 　　　　 OOO-OOOOO-OO - OO - 8O Normally 　　　　　 R&D Parts Number 14 digits 10+2+2 Item Master Process OOO-OOOOO-OO - OO - OO 　 　　　　 Item Number of BOM 22 digits OOOO Supplier 　 OOOO User 　　　　 10+2+2+4+4 　 / 　 Code 　 When Supplier is same to User 　　　　　　　　 Manufacturing 　 When Supplier is different to User 　　≠　　　　　 Transportation 5VT-H1450-00-00-80-9110-9110 Title Sub Title BOM Basic Education PYMAC ITEM YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div Title BOM Basic Education Sub Title PYMAC ITEM YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div Item Number & 　 Item Master ( For Raw Materials) PYMAC only control raw materials that we can calculate consumption for producing FGS Example: Magnet wire, Resin, Hose, Cord High tension, Solder Pymac Item No  Pymac Item Name Kind or material SUPPLIER USER D0100-00001 CORD HIGH TENSION D 1018 9140 D0200-00001 HOSE D 1001 9140 A0100-00001 MAGNET WIRE A 1015 9120 A0100-00002 MAGNET WIRE A 1015 9120 A0100-00001 MAGNET WIRE A YEVN, 1006 9120 A0200-00001 MAGNET WIRE A 1006 9130 A0200-00003 MAGNET WIRE A 1006 9130 A0200-00002 MAGNET WIRE A 1006 9130 A0100-00002 MAGNET WIRE A 1006 9120 A0200-00004 MAGNET WIRE A 1006 9140 A0200-00005 MAGNET WIRE A 1006 9140 A0200-00006 MAGNET WIRE A 1028 9140 C0100-00001 EPOXY - ST MOTOR C 1018 9130 C0200-00001 EPOXY RESIN K-8174(A) C 1018 9130 C0200-00002 EPOXY RESIN K-8174(B) C 1018 9130 C0100-00002 EPOXY(adhesive) SOMAR C 1018 9110 C0100-00003 EPOXY RESIN C 1019 9130 C0200-00003 EXPOXY RESIN (A) C 1029 9140 C0200-00004 EXPOXY RESIN (B) C 1029 9140 B0100-00001 SOLDER PASTE B 1021 9150 C0200-00005 UE-947A C 1027 9150 C0200-00006 UE-947B C 1027 9150 B0200-00002 SOLDER BAR B 5010 9150 Item No is decided by not YGK Title BOM Basic Education Sub Title ITEM CLASS Catagory YEVN PYMAC -III YEVN-18 th Apr 2013 ITEM CLASS Example Raw material A0100-00001 MAGNET WIRE Normal Part 5TN-85559-00-00-80 ROTOR Made by: PC div Title BOM Basic Education Sub Title YEVN PYMAC -III YEVN-18 ITEM STATUS th Apr 2013 Made by: PC div Item Status changing steps Check existing in PROPAC/G-FAST part master System processing :automatic by monthly For Service part 　 Service part 　 　 　 　 　 Impossible Pilot First Mass Production Production Production Delete manufacturing 　 Discontinued Mass delete production 2times/year Non Service part item Utilize by Pilot production Order Check sheet Rejection of for the initial Die, Mold and JIG Supply part another system or manual operation Title Sub Title BOM Basic Education YEVN PYMAC -III YEVN-18 REVISION NOTICE th Apr 2013 Made by: PC div Two types of Revision (Technical/Manufacturing) Priority Technical The highest priority apply for initial production A revision revision to be applied B1 Revision Manufacturing as soon as New parts are available B2 when Old part stock has been used D deal with procedural changes only B1 revision BOM Revision BOM revision has two types of data, Effective date and revision No Effective Date + Revision Number Example; Technical revision =When new parts will start production (Supply) / or finish to use old parts Use technical revision number for technical revision Otherwise, use ‘Original’ revision number for manufacturing revision Manufacturing revision 5TP5A25 (upon YGK rule) 143Z1A1 (arbitrary No.) 5TL5525 Numeric: Local R&D Title Sub Title BOM Basic Education YEVN PYMAC -III YEVN-18 REVISION NOTICE th Apr 2013 Out/In Date & Rev.No Mar 31 1DB-H591A-01 Old part Same date Apr YYYY MM DD OUT Out effective date: 20130401 IN 1DB-H591A-02 Out Rev.No: 1DB1A00 New part YYYY MM DD In effective date: 20130401 In Rev.No: 1DB1A00 Same Rev No Out effective date… From this day, old part will be not effective ** = Old part will be effective until one day before Made by: PC div Title BOM Basic Education Sub Title BOM FOR PP & MRP YEVN PYMAC -III YEVN-18 Production Plan Production Plan (PP) (PP) Material Requirement Planning Material Requirement Planning (MRP) (MRP) Plan (Output) Plan (Output) +/- 0:zero Production +/- 0:zero Production th Apr 2013 Made by: PC div Organization Master (definition of S/U code , etc ) BOM Item master, Product Structure Order by required Item / Time / Quantity 　 Depend on Order policy, Demand policy and Lead Time 　 Receive/ Manufacture/ Delivery Plan ( also Extra order) Strictly upon the production schedule 　　　　　　　 Manufacturing result report (Inventory, Inventory on order) Inventory Control Inventory Control 　　　　 　　　　 Receiving report / Completion report / Safety stock 　　　　　　　　　　　　　　　 　　　　　　　　　　　　　　 Title BOM Basic Education Sub Title 10 MRP ( Material requirement plan) YEVN PYMAC -III YEVN-18 th Apr 2013 Master Production Schedule (MPS) Gross required Manufacturing Quantity calculation Gross required Quantity Order (Start date) BOM 　　　 Preceding Calculation Inventory Lead time 　　　 Inventory on 　　　　　　 Calculation of Net required quantity Order 　　　 Order policy 　　　　 Manufacturing Net required Order (Paying out date) Quantity Lot sizing Made by: PC div Title BOM Basic Education Sub Title 10 MRP ( Material requirement plan) YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div MRP information provide all Pur parameters: 　 Order policy, Demand policy and Lead Time, Packing Capacity, Stock Location, etc MRP demand policy Load sum code MRP demand policy Order Policy MOQ MOQ Packing capacity Title BOM Basic Education Sub Title 11 STOCK LOCATION YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div YEVN Standard Definition of Stock Location code Category Stock Loc Stock Location (P/F, S/P) axx Comment x = alpha-numeric (0,1,…9,a,b,…y) *except i,o,q,z SU_code Location(P/F) Location(S/P) ROTOR ASSY Line A** A** STATOR ASSY STATOR ASSY Line B** B** 　 　 COIL ASSY Line C** C** 　 　 PULSER D** D** STARTING MOTOR ASSY Line E** E** STATOR Line F** F** ARMATURE Line G** G** IGNITION COIL ASSY IGNITION COIL ASSY H** H** 　 IGNITION COIL COMP J** J** UNIT ASSY CDI UNIT ASSY K** K** 　 　 CIRCUIT BOARD ASSY L** L** 　 　 SMT M** M** NON PROCESS - N** N** 9110 9120 9130 SU_name ROTOR ASSY STARTING MOTOR ASSY 　 　 　 　 9140 　 9150 9900 WC_name ED D I EC D T O N digit : W/C digit : Area 1~3 > P/F 4~5 > Room 6~7 > Old Factory 8~9 > Line A~Z > S/P digit : Detail - Shelf, Area, … Title BOM Basic Education Sub Title YEVN PYMAC -III YEVN-18 12 LOAD SUM CODE YEVN Standard Definition of th Apr 2013 Used Usedby by summarized summarizedProduction ProductionPlanning, Planning, Sequence Sequenceof ofProduction Productionschedule schedule Load Sum code Category Load Sum All Comment x = numeric a1x (0,1,…9) * : 0-9 SU_code SU_name WC_name Load_sum_code 9110 ROTOR ASSY ROTOR ASSY Line A11 9120 STATOR ASSY STATOR ASSY Line B11 　 　 COIL ASSY Line C11 　 　 9130 　 STARTING MOTOR ASSY 　 ED D I C DE PULSER D11 STARTING MOTOR ASSY Line E11 STATOR Line F11 ARMATURE Line G11 IGNITION COIL ASSY IGNITION COIL ASSY H11 　 IGNITION COIL COMP J11 UNIT ASSY CDI UNIT ASSY K11 　 　 CIRCUIT BOARD ASSY L11 　 　 SMT M11 NON PROCESS - 　 9140 　 9150 9900 　 - Made by: PC div Title BOM Basic Education Sub Title YEVN PYMAC -III YEVN-18 13 WORK CENTER YEVN Standard Definition of th Apr 2013 Made by: PC div Used Usedby bySummarize Summarizecapacity, capacity,MRP MRPInformation Information‘s‘skey key Input work center code Category Input W/C All a01 Comment a = alpha-numeric (User Definable) SU_code SU_name WC_name 9110 ROTOR ASSY ROTOR ASSY Line1 A01 9120 STATOR ASSY STATOR ASSY Line1 B01 　 　 COIL ASSY Line2 C01 　 　 PULSER D01 STARTING MOTOR ASSY Line1 E01 STATOR Line1 F01 ARMATURE Line1 G01 IGNITION COIL ASSY H01 　 IGNITION COIL COMP J01 UNIT ASSY CDI UNIT ASSY K01 　 　 CIRCUIT BOARD ASSY L01 　 　 SMT M01 NON PROCESS - 9130 STARTING MOTOR ASSY 　 　 　 　 9140 　 9150 9900 IGNITION COIL ASSY ED D I C DE Input _WC - Title BOM Basic Education Sub Title 14 Operation : How to input BOM YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div 　 Current operation 　 1) 1)Gathering Gatheringinformation information 2) 2)Making MakingBOM BOMfor forProd Prod 3) 3)Check Check//Approval Approval No double check operation PC Drawing 4) 4)Input InputBOM BOM No process of approval R/N 　 Mistake of input PC receive “Drawing” and “R/N” from 　 Mistake of R/N PC gather information from QA div After that think of BOM for 　 Mistake of qty info each div and it takes long time Manufacturing Input “PS_table.xls” to collect completely Sometimes by oral Lots of problems can be happened!!! 　 PYMAC operation 　 1) 1)Gathering Gatheringinformation information 2) 2)Making MakingBOM BOMfor forProd Prod PC Drawing 　　 3) 3)Check Check//Approval Approval PC 　　　 Add info Item Master 4) 4)Input InputBOM BOM Item Master Add info Item Master R/N Registration Format Registration Format Registration PIC must check its contents Based on the information of Format and sigh it registration format, input these Info to PYMAC BOM module 「 Registration format for “ Item master”/ “BOM” 「 Double check operation must be sent around each div and it’s easy to gather info And BOM accuracy will be high Title BOM Basic Education Sub Title 14 WORK FLOW: How to input BOM YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div Title BOM Basic Education Sub Title 15 Operation : How to register ST YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div 　 Current operation 　 1) 1)Register RegisterItem/BOM Item/BOM 3) 3)Make Makeregistration registrationformat format 2) 2)Time TimeST ST 4) 4)Input InputST ST 5) 5)Use Useof ofST STinfo info PC PC Each div control ST data by their own There are no connection 　 PROD between PC info and PE info 「 No registration format Add New item to P 　 I 「 Not clear rule of approval “ST_master.xls.” 「 Not unified control of ST NO relation 　　 ACC 　　　　 　 PYMAC operation 　 1) 1)Register RegisterItem/BOM Item/BOM 3) 3)Make Makeregistration registrationformat format 2) 2)Time TimeST ST PC PE 4) 4)Input InputST ST PC Action S/R 5) 5)Use Useof ofST STinfo info PC Man/Capacity plan 　 Send Information of Drawing Action S/R to PE div trial PROD 　 STDTime From Capacity plan Input Item/BOM information P 　 to PYMAC system When Whennew newitem itemoccurred, occurred,PYMAC PYMAC BOM registration format Based on the information Receive approval from PE div., PC input it into PYMAC system(BOM module) system system shows shows “Action “ActionS/R”(alarm) S/R”(alarm) time 　 Man/Cycle) 　 Unified control 　 Kaizen Activity 　　　 Cost control 　　　　 Plan/Actual management Title BOM Basic Education Sub Title 15 WORK FLOW : How to register ST YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div ... 5VT-H1450-00-00-80-9110-9110 Title Sub Title BOM Basic Education PYMAC ITEM YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div Title BOM Basic Education Sub Title PYMAC ITEM YEVN PYMAC -III YEVN-18 th Apr 2013... Ensure BOM accuracy rate 100% Title BOM Basic Education Sub Title ORGANIZATION STRUTURE YEVN PYMAC -III YEVN-18 th Apr 2013 Made by: PC div Title BOM Basic Education Sub Title S/U code YEVN PYMAC. .. Shipping 　　　　 　　　　　　　　 Made by: PC div Title BOM Basic Education Sub Title YEVN PYMAC -III MANUFACTURING PROCESS AND BOM YEVN-18 th Apr 2013 BOM BOMDisplay Displaywith withManufacturing ManufacturingProcess