MS-9000Manual.docx

BenjTSManufacturingMaterialsManagementManualThismanualexplainstheplanforsatisfyingFordMotorCompany9SMS-9000requirements.Thismanualisintendedtobeusedinseminarworkshops.Theformatandcontentcanbeusedtoassistcompaniesindevelopingtheirownmaterialsmanagementmanual.Ifthismanualisusedasatemplate“theuserneedstobeawarethatthismanualdoespurposelynotaddresssomeMS-9000requirements.Theresponsibilities,authoritiesandimerreIationsforthosethatmanageyperformandverifythematerialsmanagementsystemwillbeidentifiedthroughtheuseofproceduresandworkinstructions.TheactivitiestobeperformedwillidentifythemanagerwhowillestablishandimplementtherequiredprocedureforsupportingtheoperationsoftheMaterialPlanningandLOgiStiCS(MP&L).Themanufacturingsystemmanagementrepresentativeisresponsibleforfimplementing,maintaining,andensuringthatallpersonsinvolvedwiththematerialmanagementsystemunderstandtheobjectives,Benji9SManufacturingisdedicatedtoachieving100%ontimedelivery,everimprovingthemanufacturingcycletime(MCT)9inventoryturnsandsubcontractordeliveryperformance.Jobdescriptionsforallpersonsinvolvedinthematerialplanningandlogisticsfunctionsareavailableinthehumanresourcefiles.Themanufacturingsystemmanagementrepresentativeisresponsiblefor,providinganupdatedcontactlist(includingtopmanagement),tothecustomer.Customercontactswillbeavailableduringallcustomerworkinghours.TheAQPprocedure(100-ENGR-XX)includestheappropriateMP&Lpersonnel.TheseindividualsparticipateinandsignoffontheAQPprocess.TheAQPprocessevaluatesUseergonomicstoassureefficientemployeeoperationsinmaterialsmanagement.Keymeasurements,thatverifythesuitabilityandeffectivenessofthematerialsmanagementPrOCeSs,areincludedinBenji9SManIifacturingQOS.BenjVsManufacturingperformsannualself-assessmentsoftheQOSusingtheFordQOSAssessmentandRatingProcedure.RecordsoftheQOSreviewsandannualself-assessmentsaremaintained.BenjifSManufacturinghashousekeepingpracticesthatarecoveredwithallemployeesduringnewemployeeorientation.Thesepracticespromoteasafe,efficientworkenvironment.Housekeepingprocessauditstakeplaceweekly.Recordsareavailableinthemanufacturingsystemmanagementrepresentativefiles.4.2 MaterialsManagementSystemBenji9SManufacturinghasestablishedanddocumentedthismanagementmanualthatcoverstherequirementsofMS-9000.Themanual,relatedprocedures,workinstructionsandrecordswillbemaintainedtoensurethatthecustomerreceivestherightquantityrightproduct,attherighttime.Thismanualwillindexthematerialsmanagementsystemproceduresandworkinstructions.TherelatedprocedureswillsatisfytherequirementsofMS-9000.Placeacurrentmaterialflowdiagramforthefacilityinthislocationofthemanual.BenjifsManufacturingusesmotionstudiestooptimizethematerialflowthroughtheoperation.Themotionstudiesfocusonnon-value-addedworkandtimedelays.Thesestudiesareincluded加thecontinuousimprovementeffortsoftheQOS.4.3 ContractReviewZCiistomerInterfaceAspartoftheContractReviewProcedure(100-SM-CR-XX)9Benji9sManufacturingidentifiespotentialdeliveryproblemsandcommunicatesthentothecustomerwhentheyareidentifiedduringthecontractreviewactivities.Thecustomerisalsocontactedconcerningallerroneousinformationthatcanaffecttheabilitytomeetrequirements.Resolutionsonallunresolvedissuesarerequiredtobefoundanddocumentedpriortotheclosingofcontractnegotiations.Duringcontractreview,customerrequirementsconcerninganinteractiveinventorymaterialsmanagementsystemsuchasDirectDataIJnk(DDL)isaddressed.Ifaninteractiveinventorysystemisused,dailyshortagesandnewmodellaunchrequirementsareaccuratelyansweredinaccordanceWithFordprocedures.Informationisavailabletothecustomerthroughouttheiroperatinghours.Theorderentryprocedure(orderentryIll-SM-OE-XX)ensuresthatthemethodofcustomerapprovalisestablishedensurethatinitialshipmentsofnewmodelmaterialsarenotmadewithoutcustomerapproval.ThisprocedureisalsousedtoreconcilecumulativeshipquantitydisagreementswithcustomerinatimelymannerThetoolingmanagementprocedure(110-ENGR-TM-XX)requiresthatcustomerapprovalisreceivedpriortodisposingorreworkingtooling.Electronicdatainterchange(EDI)systemthatinputsAIAGEDI830transactionsandEDI866sequencedshiprequirementsareaddressedaspartoftheadvancedqualityplanningprocedure.TheEDIinputentersdirectlyintotheschedulingsystem.Theschedulingsystemisorderdriven.Theschedulingsystemdoesallowtheoptionofbuildingtoaninventoryifrequiredby(hecustomerorthecustomersshorttermforecastingabilityhasproventobeuntrustworthy.Theseoptionsarecontrolledthroughtheuseoftheproductionschedulingprocedure(120-PC-PS-XX),Theschedulingsystemmaintainsparameters(subcontractorleadtimes,manufacturingcycletimes,shippingtimes,andresourcerequirements)tocorrelatemanufacturingrequirementswiththecustomersshiprequirements.Thepurposeofthesystemistominimizetherequirementsforpremiumfreight.Thesystemautomaticallyperformscomparisonsofcapacityandthecustomerrequirementprojections,bypartduringtheorderentryprocess.Allfilesarebatchedandprocessedduringthefirstshifttolookattheentiresystemformaterialandprocessingconstraintsthatmightaffectdelivery.Thesystemhaspl