Supplier Quality Improvement Manual - :: Welcome To · PDF fileSupplier Quality Improvement Manual Description Page ... -Packaging and Label correct as standard WH -Packaging and Label

Supplier Quality Improvement Manual

Description Page

1.Material order Flow Process

- Material Order Flow 1/13

- Material Order Flow Explanation 2/13

- Sample of MMPP 3/13

- Sample of MDS 4/13

- Sample of SDS 5/13

- Sample of Tag Barcode 6/13

- Sample of Capacity Survey 7/13

2.Supplier Delivery Evaluation 8/13

4.Supplier Delivery Abnormal Flow

CONTENT

PRODUCTION CONTROL SUPPLIER MANUAL

-Supplier Delivery Abnormal Flow 9/13

-Supplier Delivery Delivery Problem Report 10/13

-5Why Analysis Form 11/13

5.In-Charge of Production Control

-IPP 12/13

-ESIE 13/13

Production Control Supplier Manual


1. Material Order Flow

MMPP = MONTHLY MATERIAL PURCHASE PLAN

1. TER will issue MMPP 1 time/month as normally and send to supplier

23‐26 of every month by e‐mail as PDF file and send revise case by case

2. Supplier has to check all concern data and reply confirmation to TER

within 3 day after receive MMPP by e‐mail or FAX

3. If supplier can't support forecast, please write down the problem

in MMPP or call to TER for urgent for discuss

ACTIONSSUPPLIERPC STORAGE/WAREHOUSE

TER

MMPPMMPP

MMPPCONFIRMED

6 M CHECK

MMPPCONFIRMED

MDS = MATERIAL DELIVERY SCHEDULE

1. TER will issue MDS 3 times/month (order 10 days) and send to

supplier before delivery date 3‐5 days by e‐mail as PDF file.

2. Supplier has to check all concern data and reply confirmation to TER

within 2 days after receive by e‐mail or FAX

3. If supplier can't deliver follow MDS, please write down reason in

MDS or call to TER for urgent case

4. After confirm, if supplier can't deliver follow MDS, supplier should

inform TER by issue amendment at least 1 day before delivery date

5. TER will send PO, TAG, SDS before delivery date 2 days by e‐mail as

PDF file

6. TAG, supplier has to use paper colour for tag print out follow TER

regulation

7. TER will accept invoice only, if can't issue invoice, needs to inform

TER for accept case by case for temporary invoice

MDSMDS

6 M CHECK

PO

TAG

MDSCONFIRMED

D/O

MATERIAL

TAG

INVOICE

MDSCONFIRMED

MATERIAL

TAG

INVOICE

Page 1 of 13 Production Control Supplier Manual


1. Material Order Flow Explanation

‐Monthly Material Purchase Plan (MMPP)

1.MMPP (Estimated and Forecast) will be issued 1 time/month

2.MMPP will be send to supplier by E‐mail (PDF File) at least 5 days before next month

3.Supplier checked and confirm back to TER within 3 days after received MMPP

‐ Material Delivery Schedule (MDS)

** Metal and Rubber Parts

1.MDS will be issued every 10 days (3 Times/Month)

2.MDS will be send to supplier at least 3 days before due date

3.Supplier checked ability and confirm back to TER within 2 days

**Rubber Compound

1.MDS will be issued every Tuesday for order 7 Day

2.MDS will be send to supplier at least 7 days before next due date

3.Supplier checked ability and confirm back to TER within 2 day

**Precision Product (PP) and Plastic Hose Parts (PH)

1.MDS will be issued twice per month



**Chemical ( CR code only such as CRIS010327 )

1.MDS will be issued every month (about 25th of every month)



‐Purchase Order

1.P/O will be issued follow MDS (P/O No. shows in MDS)

2.P/O will be send to supplier by E‐mail (PDF File)

‐Tag Barcode

1.Tag Barcode will be issued follow P/O

2.Tag Barcode will be send to supplier by E‐mail (PDF File)

3.Tag Barcode must be affixed with box when delivery to TER



1. Monthly Material Purchase Plan Form

TOKAI EASTERN RUBBER (THAILAND) LTD.111/3 Moo 2 Soi Nikom 13 Rd. T.Makhamkoo, Amphur Nikompattana Rayong 21180 Thailand.TEL : 038-893-557 EXT.185, 186 FAX : 038-893263

SUPPLIER : LNXXXXX ABCXXX CO.,LTD.TEL NO : 038-XXXXXXFAX NO : 038-XXXXXX

Item code Mfg.No January February March April

M0TM231J30 TM-231J-3 54,417 56,419 57,309 50,517

M0TM231J40 TM-231J-4 54,417 56,419 57,309 50,517

M0TM232J30 TM-232J-3 122,763 126,945 133,006 112,222

M0TM232J40 TM-232J-4 122,763 126,945 133,006 112,222

M0TM233H30 TM-233H-3 54,300 56,324 57,164 50,437

Monthly Material Purchase Plan (IPP)


, , , ,

M0TM233H40 TM-233H-4 54,300 56,324 57,164 50,437

M0TM234K30 TM-234K-3 122,418 126,600 132,661 111,877

M0TM234K40 TM-234K-4 122,418 126,600 132,661 111,877

707,794 732,576 760,278 650,104

S : Spare Part

Please sign "Supplier Confirmed" and reply to TER within 3 Day after received.

TOTAL

Supplier sign Confirm and reply to TER

Please sign "Supplier confirmed" and reply to TER within 3 days after received


1. Material Delivery Schedule Form

Material Delivery Schedule

Tokai Eastern Rubber (Thailand) , Ltd. Supplier : LN00890

111/3 Moo2 Soi Nikom 13 Rd. T.Makhamkoo, Siam Chuyo Co.,Ltd.

Amphur Nikompattana Rayong 21180 Thailand. Tel. No. : 038-955767-9 Ext.209

Tel. : 038-893557-61 Fax. : 038-893263 Fax. No. : 038-955780

1 TM-231J-3 M0TM231J30 200 3000 3000 3000 3000 3000 3000 3000 21000

2 TM-231J-4 M0TM231J40 400 2800 2800 2800 2800 2800 2800 2800 19600

3 TM-232J-3 M0TM232J30 200 6000 6000 6000 6000 6000 6000 6000 6000 48000

4 TM-232J-4 M0TM232J40 400 6000 6000 6000 6000 6000 6000 6000 6000 48000

5 TM-233H-3 M0TM233H30 150 2400 2400 2400 2400 2400 2400 2400 2400 19200

26 27 28 29 30 TOTAL

21 - 31 January 2013

NO MFG.NO ITEM CODE PCS/BOX 21 22 23 24 25

5 TM 233H 3 M0TM233H30 150 2400 2400 2400 2400 2400 2400 2400 2400 19200

6 TM-233H-4 M0TM233H40 400 2400 2400 2400 2400 2400 2400 2400 2400 19200

7 TM-234K-3 M0TM234K30 150 6000 6000 6000 6000 6000 6000 6000 6000 48000

8 TM-234K-4 M0TM234K40 400 6000 6000 6000 6000 6000 6000 6000 6000 48000

5601354 5601355 5601356 5601357 5601358 5601359 5601360 5601361ORDER NO. (PM) PO. NO.

Please sign "Supplier confirmed" and reply to TER within 2 days after received Supplier sign Confirm and reply to TER



1. Tag Barcode System Document

-Sample of Summary Delivery Sheet



1. Tag Barcode System Document

-Sample of Tag Barcode, The colour will change follow WH rule



Sample of Capacity Survey

Tokai Eastern Rubber(Thailand) Ltd.Summary Supplier Capacity Report 2013Supplier : Report Date :Report By :

Q'ty mold TER Peak Volume Judge

or die (22 days) (26 days) (Apr'13 - Mar'14)

NO OK

NO OK

NO OK

NO OK

NO OK

NO OK

**If judge "NO OK" Please take countermeasure

Remark : ในกรณีทีว่ันทํางานไมอยูในขอบเขตทีท่าง TER กําหนด(22 และ 26 วันทํางาน)ทาง supplier สามารถแกไขใหตรงกับวันทํางานจริงได

CountermeasureTER ITEM CODE TER MFG Cap/DayQ'ty Cavity/mold/die Cap / 1 hr.Cap/Month

Issued Checked Approved


Report Date วันที่ทําการสงรายงานใหกับ บ.โตไก

Report By ผูสงรายงาน

TER ITEM CODE ช่ือสินคาของ TER

TER MFG รหัสสินคาของ TER

Q'ty mold or die จํานวนแมพิมพที่มีที่ Supplier (ในกรณีที่ทาง supplier มีการใช mold และ die common กัน

ตองทําการคํานวณ capacity โดย share percent load ของแตละช้ินงานใหชัดเจน)

Q'ty Cavity/mold/die ปริมาณช้ินงานตอแมพิมพ

Cap/ 1hr. ความสามารถในการผลิตตอช่ัวโมง

Cap/Day ความสามารถในการผลิตตอวัน โดยไมรวม OT โดยเลือก Process ที่ความสามารถต่ําสุด

Cap/Month ความสามารถในการผลิตตอเดือน โดยไมรวม OT (วันทํางานถาไมอยูในขอบเขตท่ีทาง TER กําหนด

สามารถเปล่ียนแปลงไดตามวันทํางานของ บริษัท Supplier)TER Peak Volume (Oct'12 - Mar '13) ใหใสจํานวน Forecast ที่สูงที่สุดระหวางเดือน Apr-Mar ตาม MMPP (Oct'12 - Mar '13)

Judge ผลของการเปรียบเทียบระหวาง กําลังการผลิตตอเดือน กับ TER Peak Volume

OK = Capacity/Month > TER Peak Volume

NO OK = Capacity/Month < TER Peak VolumeCountermeasure ในกรณีที่ความสามารถในการผลิตตอเดือน นอยกวา TER Peak Volume

ให Supplier ใสปญหาพรอมวิธีการแกไขเพ่ือใหสามารถรองรับคําส่ังซ้ือได


PURPORE : For inform supplier about delivery performance in monthly to find cause,problem for correction.

Effective date : June 1st, 2013

2. MONTHLY DELIVERY EVALUATION

SCOPE : For supplier who send Raw Material to TER.

DEFINITION : TER will use "Supplier Delivery Evaluation Criteria" to inform supplier about monthly delivery performance that evaluated from this criteria

SUPPLIER DELIVERY EVALUATION CRITERIA

DELIVERY CRITERIA TO GET SCORE 15

No. Score PIC. No. Score PIC.1 Delivery Schedule 1 Delivery Performance

-On time but have premium freight WH -On time but have premium freight 10 WH-Delay delivery but have not affect to production plan WH-Delay delivery and affect to stop line WH

2 Delivery Quality 2 Delivery Quality-Correct for type of material WH -Correct for type of material WH-Correct for quantity WH -Correct for quantity WH-Packaging and Label correct as standard WH -Packaging and Label correct as standard WH-Correctly and Completely delivery document and other WH -Correctly and Completely delivery document and other WH

3 Communication and Cooperation 3 Communication and Cooperation

-10/time

NewItem Y2012 (rev.01) Item Y2013

20-5/time-1/time-1/time-1/time

-20/time20

20-1/time-1/time

-20/time

Current

PROCEDURE WHEN SUPPLIER HAS PROBLEM:

1. IF SUPPLIER GOT RANK "C" CONTINUE 2 MONTH, SUPPLIER'S TOP MANAGEMENT HAS TO REPORT COUNTERMEASURE AT TER

2. IF SUPPLIER GOT RANK "D", SUPPLIER'S TOP MANAGERMENT HAS TO REPORT COUNTERMEASURE AT TER

IPP PLANT : MS.KANYANEE, MS.SIRERATTEL.(038) 893‐557‐61 EXT.185,186 FAX.(038) 893‐263ESIE PLANT : MR.UAYCHAI, MS.NAMFON, MR.KAMCHAITEL.(038) 927‐500 EXT.309,635,634 FAX.(038) 893‐263

***IF YOU HAVE PROBLEM DELIVERY EVALUATION SCORE ,PLEASE CONTACT

p p-Reply MMPP, MDS, Capacity survey and Letter on PC -Reply MMPP, MDS on time requestd 5 PC time requestd -Reply Capacity survey and Letter on time requestd 5 PC-Reply Supplier delivery problem report on time PC -Reply Supplier delivery problem report on time 5 PC

4 Accident in TER (minus from total score) -5 WH 4 Accident in TER (minus from total score) -5 WH

5 Production Stop line (minus from total score) -20 PC

-1/time

-1/time-5/time

-20/time

-5/time -5/time

5-1/time

-1/time

RANK SCORE DESCRIPTION JUDGEMENTExcellent 100 Excellent

A 97‐99 Very GoodB 90‐96 GoodC 85‐89 Need ImprovementD <85 Need Improvemen&Report to TER

Acceptable

Unacceptable



4. Example of Supplier Delivery Problem ReportDOC.NO.TES‐PF‐0001 DCR.NO.42039 REV. 10 EFFECTIVE DATE : 1/05/2013

REPORT DATE

REPORT NO.

FROM:

PROBLEM P.I.C.

DETAIL OF TROUBLE

1 Delivery Perforemance

1.1 On time but have premium freight ‐10/คร้ัง

‐ จัดสงตรงเวลาแตมีคาใชจายเน่ืองจากการขนสง

2 Delivery Quality

2.1 Correct for Q'ty & type of material

‐ จํานวนของชิ้นงานที่จัดสงไมถูกตอง

‐ ชนิดของชิ้นงานที่จัดสงไมถูกตอง

2.2 Packaging & Label correct as standard

‐ ปายช้ีบงและบรรจุภัณฑไมตรงตามมาตรฐาน

2.3 Correctly & completely delivery document and other

‐ เอกสารท่ีเก่ียวของกับการจัดสงไมถูกตองและไมสมบูรณ

3 Communication

3.1 Reply MMPP,MDS,Capacity survey & letter

‐ ไมตอบกลับเอกสาร MMPP, MDS ‐1/คร้ัง

‐ ไมตอบกลับเอกสาร Capacity Survey ‐5/คร้ัง

‐ ไมตอบกลับเอกสารอ่ืนๆภายในเวลา ‐1/คร้ัง

10

20

15

‐20 /ครั้ง

SUPPLIER DELIVERY

PROBLEM REPORT SUPPLIER NAME :

APPROVED BY CHECKED BY REPORT BY

TER

เกณฑการประเมินการจัดสงของบริษัทผูสงมอบ ใบตัดคะแนน

ลําดับท่ี หัวขอการประเมินผล เต็มเกณฑคะแนน

วันที่

IPP ESIEMINOR MAJOR

8

9

10


ๆ4 Accident in TER (หักจากคะแนนรวม กรณีละ 5 คะแนน)

‐ มีอุบัติเหตุเกิดขึ้นภายใน TER

1 2 3 4 5 6 7 5 Production Stop line (หักคะแนนรวม กรณีละ 20 คะแนน)

‐ ไมสงชิ้นงานสงผลให line การผลิตหยุด ‐20

8 9 10 11 12 13 14

CAUSE CORRECTIVE ACTION

RECORD FOR TER APPROVING & CLOSE

REMARK : MAJOR REPLY REPORT WITHIN 3 WORKING DAYS , MINOR REPLY REPORT WITHIN 7WORKING DAYS

Keep 3 years

‐5PROBLEM FREQUENCY(TIMES)

SUPPLIER

TER SUPPLIER

SUPERVISOR PIC SECTION MGR PIC

MANAGEMENT MANAGEMENT

Rev.No Date Detail10 1/5/2013 เกณฑการประเมินการจัดสงของบริษัทผูสงมอบ9 1/10/2013 หัวขอการประเมินผลและเกณฑการใหคะแนน

8 12/1/2012 เกณฑการประเมินการจัดสงของบริษัทผูสงมอบ


3. Supplier Delivery Abnormal Flow

Purpose : To inform supplier about delivery problem and how to reply countermeasure of each case

Scope : When will TER issue :

‐Supplier Delivery Problem Report?

‐ When will supplier reply countermeasure?

‐How to reply countermeasure?

Definition : If TER found delivery problem, TER'll issue "Supplier delivery problem report" to inform

problem to supplier, Supplier has to find route cause and reply countermeasure to TER up to NG case

Minor case : reply in supplier delivery problem report and reply within 7 working day

Major case : reply in 5why form and reply within 3 working day

Remark : PC will be issued Supplier delivery problem Report in case " Stop line " only

Flow of Supplier Delivery AbnormalPC issue "Supplier delivery problem

Report" and record report list

Not accept

Supplier reply "Supplier Delivery Problem

PC Follow up"Corrective Action"

Supplier analyze rootcause, do corrective and preventive action

Inform Supplier by send "Supplier Delivery Problem Report"

Supplier Delivery Problem Report Closing

PC Supv. Reviewand PC Mgr. Judge

NG case

MajorMinor

Accept

Supplier reply "5Why analysis" form within 3 working days

Supplier Delivery Problem Accept

Not accept

Inform Supplier by send "Supplier Delivery Problem Report"

PC Follow up"Corrective Action"


Report Closing


4. Sample of 5Why analysis Form

Production Control Supplier ManualPage 11 of 13


5.TER IN CHARGE FOR PRODUCTION CONTROL

Prod. Control(Supplier Control AV & SP)

Mr.Uaychai (Mgr.)e-mail: [email protected]

Ext. 185

TER Tel. ( 038 ) 893 - 557 - 61 Fax. ( 038 ) 893 - 263

PRODUCTION CONTROL SECTION (IPP)

Ms.L.Kanyanee(Supv. ) E-mail :[email protected]

Ext.185

Ms.D.Sirerat ( Asst.Sr.Staff) E-mail :[email protected]

Ext.186

Ms.J.Kreangsak ( Asst.Sr.Staff ) E-mail : [email protected]

Ext.145

Ms.K.Aem-orn ( Staff ) E-mail :[email protected]

Ext.195



5.TER IN CHARGE FOR DELIVERY CONTROL

TER Tel. ( 038 ) 927-500 Fax. ( 038 ) 927-599

PRODUCTION CONTROL SECTION (ESIE)

Prod. Control(Supplier Control)

Mr.Uaychai (Mgr.)e-mail: [email protected]

Ext. 309

Ms.M.Namfon ( Supv. ) E-mail :[email protected]

Ext.635

Ms.M.Supattra(Dept.Sr.Staff) E‐mail :[email protected]

Ext.635

Mr.I.Panuwat ( Asst.Sr.Staff ) E-mail :[email protected]

Ext.634

Ms.B.Philaiwan ( Asst.Sr.Staff ) E-mail :[email protected]

Ext.635

AV PP,PFP,PH

Ms.Y.Kwansalinporn(Supv.) E-mail :[email protected]

Ext.635

Mr.M. Ruangwet (PC Staff) E‐mail :[email protected]

Ext.309

Mr.C.Kamchai(Asst.Sr.Staff) E‐mail :[email protected]

Ext.634


Documents

Supplier Quality Improvement Manual - :: Welcome To · PDF fileSupplier Quality Improvement Manual Description Page ... -Packaging and Label correct as standard WH -Packaging and Label