1. 1APO TES Bangladesh Furniture Manufacturing
Organization chart: Manufacturing
Operation
Chief Executive
Operation
Manager
Factory
Manager
Production
Manager
Material
Manger
Maintenance
& Engineering
Research &
Design
Production Planning
& Control
QC, Tally
Sample, Jig &
Tools maker
Tooling
Tester,
verifier
QC, Inventory
2. 2APO TES Bangladesh Furniture Manufacturing
Material management
Function
- Collect, analize and dessiminate information
about material utilisation
- Preparing the required materials
- Determine the current stock level & its value
- Ensure the materials is safe in keeping /
storage
3. 3APO TES Bangladesh Furniture Manufacturing
Materials controller
Head of department, business owners
Managers
Executives / officers
Supervisors
Clerks
Organisation chart
Duties and responsibility
4. 4APO TES Bangladesh Furniture Manufacturing
Requirement to become material
controller
Have knowledge about the materials under
their supervision
Given authority as material controller
Have full responsibility of the goods under his
care
Has facilities to safe keeping the goods
Have good knowledge about material
management
Document: stock book, inventory card etc.
5. 5APO TES Bangladesh Furniture Manufacturing
Requirement to become material
controller (cont.)
Material management:
Planning the requirement
Purchasing
Receiving
Storage
Maintenence
Inventory
Releasing for processing
Disposing
Membuat, melapor dan
menyimpan rekod:
jenis bahan
Kuantiti
nilai
6. 6APO TES Bangladesh Furniture Manufacturing
Requirement to become material
controller (cont.)
Material tendency to wear, damage, faulty &
depreciate
Mixing recipe
Compatibility of materials to product
manufactured
Rate of utilisation
7. 7APO TES Bangladesh Furniture Manufacturing
Materials properties
Physical properties:
Type
Size
Grade
Density, chemical
content etc.
Quality
Quantity
Value of materials
Material uses
Mechanical properties:
Maintenance
Storage
9. 9APO TES Bangladesh Furniture Manufacturing
Documentations (cont.)
Receiving: goods
received notes
Name
Model
Grade, quality (refer to
specifications)
Quantity
Maintenance
Mechanical
Preventive
Inventory
Quantity
Quality
Production
Material request form
- Stock card
10. 10APO TES Bangladesh Furniture Manufacturing
Raw material management
Unit: Kg., liter, ton, pieces, unit, packing, rolls,
drums etc.
Safe keeping and safety of materials
Reports to superior officers & frequency
Not leaking information to competitors
Applying system: Location, storage methods,
replenish
Knowing stock levels and utilization rate
11. 11APO TES Bangladesh Furniture Manufacturing
Responsibility of Material
Controllers
1. Material inspection:
Before delivery (at suppliers warehouse); 2nd party audit
Ability of suppliers: to supply on time, delivery
Right information in documentations: purchasing,
delivery notes, invoice
Quality supplied according to specifications
Quality is checked
Recording the classification changes (if any & allowed)
12. 12APO TES Bangladesh Furniture Manufacturing
Responsibility of material
controllers
2. Rejects materials which doesn’t meet
specifications
Materials used to make the goods
Materials quality
Quantity
Expiry date
Non approve buyers / black listed
Disapprove brand and model
13. 13APO TES Bangladesh Furniture Manufacturing
Responsibility of material
controllers
3. Storing the materials:
Material classifications: type & physical properties
Safety levels; material depreciation, dangerous
items
Able to determine current stocks and additional
items
Taggings on materials, packages
Recording
14. 14APO TES Bangladesh Furniture Manufacturing
Responsibility of material
controllers
4. Conduct maintenance
Materials inspection
Ensure the materials is in good condition and able
to function properly
Conduct maintenance appropriatly, i.e. change the
packaging, change the tag, initiate the chemical
reactions (glue / finishing materials), eliminate
saturated components, oiling, block the undesired
chemical reactions
Separate the expired & unfunctional items
15. 15APO TES Bangladesh Furniture Manufacturing
Responsibility of material
controllers
5. Implementing inventory / audit
Count the quantity
Compare the inventory and stock card figure
Search the cause of difference, if any
Justify the quantity differences
Ensure the right quantity
Inventory / stock reports
Stock values
16. 16APO TES Bangladesh Furniture Manufacturing
Responsibility of material
controllers
6. Giving out the materials
Who can receive the materials
Approval in writing
Have needs & according to production schedule
Preparing the required materials, refer to
specifications
Exact quantity
Documentation: Material request forms,
17. 17APO TES Bangladesh Furniture Manufacturing
Factory management and
manufacturing facillities
Raw materials Machines and
manufacturing facilities
Building and compound Vehicles
18. 18APO TES Bangladesh Furniture Manufacturing
Materials classification: physical
properties
1. Main raw materials: timber & panel items
2. Processing materials: sand paper & glue
3. Dangerous materials: thinner, oil, finishings
4. Hardware: screw, hinges, connectors,
accsessories
5. Packaging: fabrics, boxes, foam, strap etc.
6. Workers: first-aid, mask, earplug, glove, measuring
tape, caliper
7. Machines: tooling and spare parts
19. 19APO TES Bangladesh Furniture Manufacturing
Storage places for raw materials
Materials is not store at one
place
Grouped to physical properties
Place to be used, processing
place
Safety structure
20. 20APO TES Bangladesh Furniture Manufacturing
Materials: Green sawn timber
Air-dried sawn timber; anisotropic
Grade: 1. Prime
2. Select
3. Standard
4. Sound
5. Serviceable
6. Utility
Stacking: a. Species
b. Size
c. Sticker
Cement flooring, even
Covered
21. 21APO TES Bangladesh Furniture Manufacturing
Timber calculations
Sawn timber
1 cu. ft. = 0.0283186 M3
1 ton = 50cu.ft.= 1.41584 M3
1 M3 = 0.7063 ton
sample:
2.25” x 3.5” x 8’, 125 pieces
Calculate in tonage?
(l x t x p)/(12 x 12 x 50) x pcs
= 2.25 x 3.5 x 8 /(7200)x 125
= 1.09375 ton
22. 22APO TES Bangladesh Furniture Manufacturing
Calculation M3
t” x l” x p” x pcs. = ft.3
1728
ft.3 = M3
35.31
Notes:
1728 = 12 x 12 x 12
35.31 = 50
1.41584
Example:
1.75” x 3.75” x 48” ada 312 pcs.
1.75 x 3.75 x 48 x 312 = 56.8749 ft3
1728
56.8749 ft.3 =1.610733 M3
35.31
56.8749 ft.3 = 1.1375 ton
50
23. 23APO TES Bangladesh Furniture Manufacturing
Materials: Kiln-dried timber
Moisture content: _ % MC
Equilibrium moisture content, EMC: 12 – 13 %
Stacking: closed stack (no stickers)
Bundled: same specie & sizes, same
lengthwise, applied wax/paint at ends, wraped
in plastics, same distance of support, 4’
Covered area, cemented, even & have walls
24. 24APO TES Bangladesh Furniture Manufacturing
Materials: dressed timber
Cut and planned to final size
Desired MC%
Bundled: same specie, same size & wrapped
Storage area: covered, cemented, even & in
building
Far from cold / heat: climate changes caused
timber to defects
Ukuran: M3
28. 28APO TES Bangladesh Furniture Manufacturing
Bahan: mouldings
Kayu berprofil
Contoh: frame, splint, skirting, jamb etc.
Bundled: sama spesis, sama profil, sama saiz,
dibungkus plastik, ikat.
Susun dalam crate
Ukuran: ft. run, mr
29. 29APO TES Bangladesh Furniture Manufacturing
Bahan: komponen perabot
Contoh: turnings, kaki, tops dll.
Berbagai bentuk, saiz dan warna
Finished & unfinished
Disusun, dibungkus & diletak ditempat teduh
Jangan simpan > 4 bulan (kayu); akan hilang
ketepatan saiz, profil
30. 30APO TES Bangladesh Furniture Manufacturing
Bahan: papan panel
Papan lapis
Binaan: lapisan venir berperekat disusun ira berselang seli
dalam bilangan ganjil
Perekat: urea formaldehyde (MR – moisture resistance) &
phenol formaldehyde (WBP – water boiling proof)
Gred: face – back; AA, BB, CC
Value added: laminated face – tego film
Susunan: jenis perekat, gred, saiz, dibungkus, kawasan
teduh
Kayu penggalas: sama saiz, jarak 2’, 6” dari hujung
31. 31APO TES Bangladesh Furniture Manufacturing
Bahan: papan panel lain
Fiberboard (MDF, HDF)
Chipboard
Softboard
Particleboard
- Binaan: habuk/serbuk/serpai kayu, berbagai saiz, digaul dengan
perekat
- Ukuran: ketumpatan, saiz (4’x8’,6’x8’,3’x6’)
- Gred: mengikut pelepasan formaldehyde; E0, E1, E2, E3
- Susunan: mengikut jenis, saiz, gred, kawasan teduh, dibungkus
plastik
- Kayu pengalas: sama saiz, jarak 2’
33. 33APO TES Bangladesh Furniture Manufacturing
Bahan: kertas pasir
Jenis: granit, kaca, silica
Gred: paling kasar (00), halus (480)
Backing: kertas, kain, plastik
Perekat: contact glue, protein
Kegunaan: mempelas, kemasiapan
Bentuk: mengikut mesin; sheet, wide belt, disc, long
belt
Simpanan: bilik hawa panas (30°C -35°C; guna lampu
15 watt)
Susunan: kepingan (disusun), gulungan (digantung)
34. 34APO TES Bangladesh Furniture Manufacturing
Bahan: perekat
Water-based, oil-based
PVAC, urea formaldehyde, contact glue, glukosa, hot
melt glue, protein, super glue etc.
Hardener, retarder
Shelve life: sebelum campur hardener
Pot life: selepas campur hardener
Standard guna: kelikatan (viscosity)
Bekas: bersih, tiada benda asing, bekas khas, kuantiti
standard i.e. 20kg, 18L
Bilik: suhu sejuk < 20°C; superglue (peti sejuk)
35. 35APO TES Bangladesh Furniture Manufacturing
Bahan: minyak
Kenderaan: petrol, diesel, cylinder, coolant,
transmission
Mesin: grease, hydraulic
Gred: SAE (kelikatan)
Ukuran: liter
Bekas khas: kedap udara, tiada benda asing,
jauh dari bangunan awam
Bilik sejuk (< 18°C), bawah tanah
36. 36APO TES Bangladesh Furniture Manufacturing
Bahan: kemasiapan
Nitro cellulose (NC), acid catalyzed (AC), poly urethane
(PU), cat, varnish, minyak
Ukuran kekuatan: resin content, solid content
Kualiti: hardness, durability, kilauan
Bahan lebur: thinner, air; retarder
Shelf life; pot life
Mudah terbakar, terpeluap
Bekas khas: kedap udara, jauh dari bangunan awam
Suhu simpanan: sejuk (< 28°C)
37. 37APO TES Bangladesh Furniture Manufacturing
Bahan: pengikat
Skru, paku, bolt & nut, staples, minifix
Spesifikasi: panjang, diameter, bentuk kepala,
bahagian pemutar, bentuk hujung, saduran,
warna
Rosak: karat, berubah warna
Bungkus: plastik, spesifikasi, kuantiti mudah
Bekas: kotak
Stor utama
38. 38APO TES Bangladesh Furniture Manufacturing
Bahan: penyambung
Hinges, connector, catches
Spesifikasi: tempat kegunaan, saiz, model #,
warna
Rosak: karat, gagal berfungsi dengan elok
Bungkus: mengikut model, plastik, kuantiti
mudah
Bekas: kotak
Stor utama
39. 39APO TES Bangladesh Furniture Manufacturing
Bahan: aksessori perabot
Tombol laci/pintu, kunci, drawer slide, toe kick,
stopper
Spesifikasi: kegunaan, saiz, warna, model
Rosak: lusuh, karat, gagal berfungsi
Bungkus: mengikut model, kuantiti mudah
Bekas: kotak
Stor utama
40. 40APO TES Bangladesh Furniture Manufacturing
Bahan: aksessori berasaskan
plastik
Screw caps, slides, adjuster, padding
Spesifikasi: saiz, warna, model
Bungkus: plastik, kuantiti mudah
Suhu: kurang dari suhu bilik (< 28°C)
Bekas: kotak
Stor utama
41. 41APO TES Bangladesh Furniture Manufacturing
Bahan: fabrik & kulit
Kain
Bahan: kapas, polyester, wool etc.
Mengikut bentuk tenunan
Spesifikasi: bahan asas, warna, lebar,
ketahanan, model
Bungkus: gulung (roll), baring, kayu / kodi
Kulit
Stor: kering, suhu > 28°C
42. 42APO TES Bangladesh Furniture Manufacturing
Bahan: pembungkusan
Kotak, PU foam, plastik wrapper, strap
Assembly instruction sheet, write up
Kotak di pipihkan, ikat
Dibungkus, bahan tidak jadi lusuh
Stor: kering, suhu > 32°C
43. 43APO TES Bangladesh Furniture Manufacturing
Bahan: keselamatan pekerja
Dusk mask, ear plug, gloves, safety shoes
Pakaian seragam, apron
Dibungkus plastik
diikat dalam kuantiti mudah
Stor utama, kering
44. 44APO TES Bangladesh Furniture Manufacturing
Bahan: alatan pengukuran
Measuring tapes, veneer caliper, gauges,
moisture meter
Simpan kering
Stor utama
45. 45APO TES Bangladesh Furniture Manufacturing
Bahan: tools
Alatan tangan: screw driver, pliers, spanner,
tukul besi, wrenches
Simpan: kuantiti mudah
Stor utama
46. 46APO TES Bangladesh Furniture Manufacturing
Bahan: mesin tooling
Knives blade, profile knives, circular saw, band
saw, drill bits, router bits
Disusun atas rak, kotak panel
Mudah karat
Senggaraan: sapu minyak
Stor mesin
47. 47APO TES Bangladesh Furniture Manufacturing
Bahan: senggaraan
Kunci: peti kunci
Tangga
Alatan elektrik: mentol, volt meter, wire
Stor sengaraan
48. 48APO TES Bangladesh Furniture Manufacturing
Mesin kecil
Jig saw, hand router, hand trimmer, drill,
screw driver dll.: elektrik & air powered
Diberi nombor rujukan unik bagi setiap satu
Nama pengguna dicatitkan mengikut tarikh &
waktu
Disimpan dalam setor alat
Dipasang mata & diuji sebelum dan selepas
dikeluarkan dari setor
49. 49APO TES Bangladesh Furniture Manufacturing
Peralatan semburan
Kemasiapan: spray gun, hos, pump, tangki dll.
Perekatan: spray gun, hos dll.
Dibersihkan selepas digunakan
Diberi nombor rujukan unik
Disimpan di setor semburan
Rekodkan nama pengguna
50. 50APO TES Bangladesh Furniture Manufacturing
Mesin tetap
X-cut saw, rip saw, moulder, panel saw, router,
drill, sander, air compressor etc.
Bekalan elektrik betul & pendawaian selamat
Alat keselamatan & tooling terkawal
Terlindung dari cuaca yang melampau
Mesin diikat dilantai rata dengan kukuh
Diberi nombor rujukan unik
Ada jadual senggaraan
Nama operator / senggara
51. 51APO TES Bangladesh Furniture Manufacturing
Peralatan kilang
Dust extractor, silo, piping, spray booth,
conveyor, hoist, work bench, perabot dll.
Ditempatkan / melalui kawasan yang
selamat.
Ditanda dengan kod warna
Diperiksa / dibersihkan secara berjadual
52. 52APO TES Bangladesh Furniture Manufacturing
Kenderaan & handling equipment
Pallet truck, forklift, roller conveyor, lori,
van, kereta dll.
Disimpan ditempat yang dikhaskan
Disenggara mengikut jadual
Operator yang dibenarkan sahaja
53. 53APO TES Bangladesh Furniture Manufacturing
Bangunan & kawasan
Bangunan, pondok, tempat letak
kenderaan, pagar, parit, tangki kumbahan,
taman, pintu, tingkap, tangga dll.
Tiada yang tersumbat, kotor, tidak terjaga
Tiada tempat pembiakan
Menugaskan anggota khusus untuk
menjaga kawasan dan bangunan
Harta benda selamat & terkawal
54. 54APO TES Bangladesh Furniture Manufacturing
TQM: Concept - TPM
5 S’s of Good Housekeeping
1) Seiri - disposal of unnecessary things
2) Seiton - make sure that things are in the
current place
3) Seiso - clean up, sweep & polish
4) Seiketsu - keep things clean - repeat 1,2 & 3
5) Shitsuke - discipline
55. 55APO TES Bangladesh Furniture Manufacturing
TQM: Concept - TPM
5 C’s of Good Housekeeping
1) Clean out - determine what is necessary &
unnecessary & dispose of the latter
2) Configure - provide a convenient, safe & orderly
place for everything & keep it there
3) Clean & check - monitor the condition of the area
during cleaning
4) Conformity - develop the habit of routinely
maintaining cleanliness
5) Custom & practice - train people in the disciplines of
the 5C’s
56. 56APO TES Bangladesh Furniture Manufacturing
5 S (Bahasa Malaysia)
Sisih
Susun
Sapu
Selia / Seragam
Sentiasa amal
57. 57APO TES Bangladesh Furniture Manufacturing
TQM: Concept - TPM
Ciri organisasi TPM
Menyatukan bahagian senggaraan &
pengeluaran
Pasukan kecil terdiri dari operator / penyenggara
Latihan menjadikan ‘operators feel like owners’
Tabiat baik membentuk:
Pembersihan menjadi pemeriksaan
Pembersihan menampakan kepincangan
Kepincangan diperbaiki
Pembaikan berterusan untuk peralatan dan
suasana
58. 58APO TES Bangladesh Furniture Manufacturing
TQM: Konsep - TPM
Step 1
(what does the company require?)
Step 2
(is everything
in order?)
Step 3
(clean up)
Step 4
(keep clean)
Step 5
(educate people
about the rules)
59. 59APO TES Bangladesh Furniture Manufacturing
TQM: Konsep - TPM
Sasaran TPM
Memaksimakan keberkesanan peralatan
Membentuk sistem PM disepanjang hayat
peralatan tersebut
Dilaksanakan di semua bahagian
Melibatkan semua pekerja
Mempromosikan PM melalui pengurusan
motivasi – aktiviti kumpulan kecil
60. 60APO TES Bangladesh Furniture Manufacturing
TQM: Konsep - TPM
5 aktiviti pembangunan TPM:
1) Menghapuskan 6 punca kerugian utama
(slide berikut) untuk memanjang hayat
peralatan.
2) Program senggaraan yang bebas
3) Program senggaraan terancang
4) Meningkatkan kemahiran anggota operasi &
senggaraan
5) Program pengurusan peralatan asas
61. 61APO TES Bangladesh Furniture Manufacturing
TQM: Konsep - TPM
Fokus TPM keatas 6 punca utama
kerugian peralatan
1) Peralatan tidak berfungsi
2) Set-up & adjustment time
3) idling & minor stoppages
4) Mengurankan kelajuan
5) Kecacatan proses
6) Mengurangkan hasil perolehan
Kumpulan kecil yang bebas fokus kepada
6 punca utama kerugian