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Material Process Flow

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by

Luis Vasquez

on 1 April 2015

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Transcript of Material Process Flow

Goal
Start
MANUFACTURING DEPT
- MTO Analysis
- Verify material delivery from Warehouse to Shop
Material Process Flow
Inventory Control
-
Drawing analysis
MTO (Material Take Off)
ENGINEERING AND DRAFTING DEPT
- BOM (bill of materials)
to include critical info (project due date, MTO's, remarks, etc)

- Runs
SAP MRP
analysis
to determine real purchase requirements.

- Create PR (Purchase Requisition)
MANUFACTURING
PROCUREMENT
PROCUREMENT DEPT
- Create / Process PO (Purchase Order)
Specify in detail different charges $ within PO (if rush, freight type, COO)
Demand quality documents to Vendor.
- FO review
- Work Pack creation
-
SAP Issue for Production
(IP) creation - FO "segmentation"
for fabrication purposes/effectiveness.
FO
IP
IP
IP
IP
IP
- Monitor delivery, based on requested project due date.
PROCUREMENT
WAREHOUSE
SHIPPING AND RECEIVING .. AND DELIVERING TO SHOP
QUALITY
QC/QA
-
Material verification
LindsayCa PO vs Vendor Packing List
Match quantities and heat numbers, verify specs.
Hand in MTRs, Certificates, MSDS to QA/QC.

-
Process GR, record Heat numbers
into SAP and print labels.
Determine if material is to consume internally or externally.
IF INTERNALLY
.- Assign BIN location and hold until an
Issue for Production
comes in to transfer material to Manufacturing Floor.
IF EXTERNALLY
.- Process
Delivery Note
(Shipping list) and deliver to
Logistics Dept.
MANUFACTURING
- Follow up material inside Fabrication Process (FP)
- Check for damaged material during the FP.
If any, need to notify ASAP to Engineering for replenishment.
- Left overs to be processed accordingly, issue a Good Return document. (Process currently to be validated)
- Monitor POs due date(s) involved to request IPs in SAP
MANUFACTURING DEPT
QUALITY DEPT
-
Certify every material
matching hard copy heat numbers vs SAP recorded heat numbers.
-
Scan hard copies or segregate PDFs
of MTRs, Certificates, MSDS, etc.
-
Identify missing MTR, Certificates and MSDS and notify
to Procurement on a timely manner.
-
Attach each file
individually by line into SAP for further referral.
WHAT HAS BEEN DONE ALREADY ..?

- INVENTORY CYCLE COUNT AND SAP ADJUSTMENT
warehouse, yard and tool room materials
- CLEAN UP INVALID / OBSOLETE SKUs IN SAP
- Finished Good item creation in SAP and raw material 16 digit SKU creation (if any new needed)
- FO (fabrication order) creation. (M
irror of BOM)
- Clear material process flow.
FINANCE
- Improve communication to optimize
invoice processing time.
- Set payment methods in accordance with project's guidelines.
- Contract milestones with payment schedule "kick off meeting"
= DOCUMENT CONTROL =
- Send RFQ's to vendors, select best option. (
include Project Mgr and Engineering Dept
for budget purposes)
FINANCE
- TEST SCANNER FOR PROPER DATA INPUT (
WAREHOUSE
)
- SAP SCREEN CUSTOMIZATION IMPROVEMENTS TO
SUPPORT DATA PROCESSING AND ANALYSIS.
- KICK OFF MEETING FOR EVERY BODY TO BE INVOLVED AND KEY PLAYERS TO BE TRAINED
- NEW ROLES TO BE DETERMINED BY NEW FUNCTIONS AS NEEDED.
THINGS TO CONSIDER ...
- Efficient turn around cash flow on each phase/project.
- Accurate materials visibility to avoid P.O. duplication.
- Increase effectiveness to detect opportunities through the process.
- SAP RFQ alignment in accordance to "project timings" to avoid rush RM deliveries.
- Send RFQ to approved vendors.
Select best option considering project's requirements (Price, LT, quality, etc)
- Get internal approvals.
-
Process IP
into the document (SAP). Assure Quality release of materials and deliver them to Shop.

- IF LEFTOVERS,
Process Good Return
accordingly in SAP.
Full transcript