Topic > Industrial Problem Analysis - 1618

In the SMD manufacturing department, small devices, such as chips, transistors, etc. they are mounted on the printed circuits using the SMD (Surface Mounting Device) machine. This SMD machine receives inputs (tiny devices) in the form of coils. The spools of the desired material are loaded onto the machine and the software does the rest of the work. Since the SMD machine requires materials in coils, there was a need for a separate warehouse, different from the raw material warehouse. The cause of this need is that the shelves of the Raw Materials Warehouse were not suitable for storing this type of sensitive devices and that finding the necessary material would take a long time since there are many coils to search for. For the reasons mentioned above, two more warehouses were built. One is SMD inventory, the other is SMD WIP inventory. These warehouses consisted of storage machines called KARDEX. KARDEX is a machine that can be mounted inside a wall and which can store and retrieve material in its trays. The model of KARDEX used in SMD inventory uses a robotic arm to fetch the requested tray and the model of KARDEX used in SMD WIP Inventory uses a chain system to fetch the requested tray. When a work order is opened for parts produced on the SMD machine, the work order form is first sent to SMD Inventory, rather than Raw Material Inventory. In the SMD Inventory, the requirements for the work order are retrieved from KARDEX and sent to the SMD WIP Inventory. That is, the use of SMD inventory is the responsibility of the production planning department. After the work order requirements are submitted and uploaded to KARDEX in the SMD WIP Inventory, the Production Department retrieves the materials needed to produce the work order from the SMD WIP Inventory. Not all work order requirements need to be recovered at the same time, partial recoveries are also possible. That is, the use of the SMD WIP Inventory belongs to the Production Department, but the responsibility for the SMD WIP Inventory belongs to the Production Planning and Control Department. The material recovery process can be seen in FIGURE PD.1 below: FIGURE PD.1 MATERIAL RECOVERY PROCESS Since the raw materials of the SMD machine are stored in reels, when the work orders arrive at the SMD inventory, the materials for more than one work order could be transferred to the SMD WIP Inventory in the same reel.