1. Organization chart: Manufacturing
Operation
Chief Executive
Operation Factory
Manager Manager
Production Planning Tester,
& Control verifier
Production Material Maintenance Research &
Manager Manger & Engineering Design
Sample, Jig &
QC, Tally QC, Inventory Tooling
Tools maker
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2. 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
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3. Materials controller
Head of department, business owners
Managers
Executives / officers
Supervisors
Clerks
 Organisation chart
 Duties and responsibility
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4. 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.
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5. Requirement to become material
controller (cont.)
Material management:

Planning the requirement
 Purchasing
 Receiving Membuat, melapor dan
 Storage menyimpan rekod:
 Maintenence  jenis bahan

Inventory  Kuantiti

Releasing for processing  nilai
 Disposing
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6. Requirement to become material
controller (cont.)
Material tendency to wear, damage, faulty &
depreciate
Mixing recipe
Compatibility of materials to product
manufactured
Rate of utilisation
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7. Materials properties
Physical properties:

Type
Mechanical properties:
 Maintenance
 Size
 Storage
 Grade
 Density, chemical
content etc.
 Quality

Quantity

Value of materials
 Material uses
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8. Documentation
Material specifications: name, model, physical
properties
Quantity: utilization rate – daily, weekly, monthly
Suppliers: name, address, telephone, products
supplied, terms and prices
Purchasing document: L.O. (purchase order),
delivery notes (D.O.), invoices
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9. Documentations (cont.)
Receiving: goods Inventory
received notes  Quantity

Name  Quality
 Model Production
 Grade, quality (refer to  Material request form
specifications)
 Quantity
- Stock card
Maintenance
 Mechanical
 Preventive
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10. 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
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11. 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)
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12. 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
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13. 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
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14. 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
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15. 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
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16. 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,
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17. Factory management and
manufacturing facillities
Raw materials Machines and
manufacturing facilities
Building and compound Vehicles
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18. 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
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19. Storage places for raw materials
Materials is not store at one
place
Grouped to physical properties
Place to be used, processing
place
Safety structure
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20. 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
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21. Timber calculations
Sawn timber sample:
1 cu. ft. = 0.0283186 M3 2.25” x 3.5” x 8’, 125 pieces
Calculate in tonage?
1 ton = 50cu.ft.= 1.41584 M3 (l x t x p)/(12 x 12 x 50) x pcs
1 M3 = 0.7063 ton = 2.25 x 3.5 x 8 /(7200)x 125
= 1.09375 ton
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22. Calculation M3
Example:
t” x l” x p” x pcs. = ft.3 1.75” x 3.75” x 48” ada 312 pcs.
1728
1.75 x 3.75 x 48 x 312 = 56.8749 ft3
ft.3 = M3 1728
35.31
56.8749 ft.3 =1.610733 M3
Notes: 35.31
1728 = 12 x 12 x 12
56.8749 ft.3 = 1.1375 ton
35.31 = 50 50
1.41584
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23. 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
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24. 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
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25. APO TES Bangladesh Furniture Manufacturing 25

26. APO TES Bangladesh Furniture Manufacturing 26

27. APO TES Bangladesh Furniture Manufacturing 27

28. 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
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29. 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
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30. 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
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31. 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’
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32. Bahan: pelapik muka
Formica, Maica
Aica
High pressure laminate (HPL); Post forming,
soft forming
- Backing: kertas, plastik, venir
- Perekat: contact glue
- Susunan: mengikut jenis, saiz, dibungkus
- Suhu: terkawal; < 24°C
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33. 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)
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34. 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)
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35. 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
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36. 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)
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37. 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
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38. 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
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39. 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
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40. 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
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41. 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
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42. 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
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43. Bahan: keselamatan pekerja
Dusk mask, ear plug, gloves, safety shoes
Pakaian seragam, apron
Dibungkus plastik
diikat dalam kuantiti mudah
Stor utama, kering
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44. Bahan: alatan pengukuran
Measuring tapes, veneer caliper, gauges,
moisture meter
Simpan kering
Stor utama
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45. Bahan: tools
Alatan tangan: screw driver, pliers, spanner,
tukul besi, wrenches
Simpan: kuantiti mudah
Stor utama
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46. 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
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47. Bahan: senggaraan
Kunci: peti kunci
Tangga
Alatan elektrik: mentol, volt meter, wire
Stor sengaraan
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48. 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
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49. 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
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50. 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
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51. 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
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52. Kenderaan & handling equipment
Pallet truck, forklift, roller conveyor, lori,
van, kereta dll.
Disimpan ditempat yang dikhaskan
Disenggara mengikut jadual
Operator yang dibenarkan sahaja
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53. 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
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54. 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
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55. 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
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56. 5 S (Bahasa Malaysia)
Sisih
Susun
Sapu
Selia / Seragam
Sentiasa amal
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57. 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
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58. TQM: Konsep - TPM
Step 1
(what does the company require?)
Step 5 Step 2
(educate people (is everything
about the rules) in order?)
Step 4 Step 3
(keep clean) (clean up)
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59. 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
APO TES Bangladesh Furniture Manufacturing 59

60. 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
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61. 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
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62. Kita tangguhkan dulu.
APO TES Bangladesh Furniture Manufacturing 62