management innovation through information system buildppt).pdf 2004-10-28 management innovation...

2004-10-28http://www.younil.co.kr

Management Innovation through Information System Build


▣ Corporate Overview ▣

The first chapter Corporate Overview

1.1 Company History1.2 Product Instruction1.3 Product Line Instruction


Company History (Since 1976-1999)

- 1976. 07 Established Younil Metal Plate at Sung-Su Dong

- 1988. 07 Renamed to Younil Industry Co. Ltd.

- 1989. 04 Acquired the first grade on trading (License 227821)

-1989. 10 PC CHASSIS OEM to Computer Marketing Department at

Hyundai

- 1991. 01 PC CHASSIS OEM to TriGem Ltd.

- 1993. 11 Licensed Gas Articles Manufacturing

- 1994. 02 Registered at SK Gas Co. Ltd.

- 1994. 12 Started to export Cabinet Heater to English

- 1996. 12 Acquired ISO9001

- 1997. 02 Acquired registration of design for 4 items and Utility Model

such as the Gas heater bottom board.

- 1997. 02 Selected a s a rosy prospect Company by Kyoung-gi

- 1997. 05 Acquired 100PPM for Qualification of goods

- 1997. 12 Awarded “the Copper Metal” at demonstration of Private &

Government management

- 1998. 09 Awarded 100PPM for the Quality improvement Action

- 1999. 07 Renamed to Younil Electronics Co. Ltd.

- 1999. 09 Acquired K.S for Portable Gas Heater

Since Since 19761976--19991999


Company History (Since 2000-Now)

- 2000. 10 PC OEM to COMPAQ KOREA

- 2001. 03 PC OEM to HYUN JU COMPUTER

- 2001. 10 PC Camera, wireless LAN, NIM, AP, LMB OEM to Samsung

Electro-mechanics

- 2002. 01 PC OEM to SAFER COMPUTER

- 2003. 10 RC OEM to SAMSUNG ELECTRONICS CO., LTD.

- 2004. 01 AIR CLEANER OEM to CHUNGPOUNG CO., LTD

- 2004. 04 DVR OEM to ELSTONE CO., LTD

Since Since 20002000--NowNow


Product Instruction

Air CleanerAir Cleaner

HP NOTEBOOKHP NOTEBOOK

-CHUNGPOUNG CO., LTD

Personal ComputerPersonal Computer -COMPAQ KOREA

-HYUN JU COMPUTER

-SAFER COMPUTER

-SAMSUNG ELECTRONICS CO., LTD.

60,000 EA/month

Digital Video Digital Video RecorderRecorder -ELSTONE CO., LTD

-IDIS

-UJUTELECOM

8000 EA/month

3,000 EA/month

HP 1,000 EA/month


Product Instruction

Server Server AssyAssy

LCD Monitor LCD Monitor AssyAssy

UNIWIDETECHNIQUES CO., LTD. 1,000 EA/month

DVD Player DVD Player AssyAssy

NEXTFEEL CO., LTD.ALPHACASET CO., LTD. 30,000 EA/month

BCT CO., LTD.

SAMSUNG CO., LTD. 30,000 EA/month


Product Line Instruction

CONVEYOR LINE (2 Line)

-CAPA: 900 EA/day(1 Line, 1 Shift)22,500 EA/month

- WORKING DAY: 25days

Product - DESK-TOP- NOTE-BOOK- LCD MONITOR

• L I N E : Auto 6Line. Manual 3Line, Paint 1Line• CAPA : 2,500 SET (p/d)

(57K ~ 60K p/m) for 23 days8Hr p/d, PC SET (Press finished good)

• Press : 80 TON ~ 300 TON total 63NC FEEDER 2

PC Assembly LinePC Assembly Line

Press LinePress Line

• NC Process, Gun Drill Process• Facilities :

Machining Center 2ea, Copy Milling, Milling 2eaBench Grinder 2ea, Tool Grinder 2ea, LatheRadial Drilling M/C 2ea, Upright Drilling 2eaWire Cutting 2ea, 3-Dimension Measuring M/C

Mold LineMold Line


▣ Driving process of information system build ▣

The second chapterDriving process of information system build

1.1 Introduction to Background1.2 Scenario1.3 System budget1.4 Build contents


Introduction to Background (Change of Environment)

We had policy and necessity of

management reform that correspond

in market environment.

We had policy and necessity of

management reform that correspond

in market environment.

We need quick and correct

information for new market strategy

about stagnation of market

economy

We need quick and correct

information for new market strategy

about stagnation of market

economy

Change of market environment

Change of market environment

We had quality mend for customer

satisfaction and the importance of

process control and necessity of

real time production management.

We had quality mend for customer

satisfaction and the importance of

process control and necessity of

real time production management.

Change of business environment

Change of business environment

E R P

+

POP

E R P

+

POP

Change of information environment

Change of information environment


Introduction to Background (Importance of system management)

1. Productivity improve by product

history management

2. Efficiency of production management

improve by real time data management

3. Maximization of Quality improvement

4. Systematization of process control

POPPOP

1. Improvement of Overload work

by manual processing document

arrangement

2. Consistency of work processing grant

3. Accuracy of data improve by

Standardization business

4. Intention and optimization of policy

decision by integral of data and

connection

ERPERP

System integral management


Scenario

Government fund application ERP(20M KW)/POP(48M KW)Select IT partner ERP(New soft techniques )/POP(e-sol)

a preliminary investigation. Interview, a field research, research datadirection Make work flow

Select Department manager, remake work processingKICK OFF

Loss improve, Design a work, make a system The first evaluation meeting

System monitoring

Take complementary listThe secondary evaluation

meeting

Make Weekly, monthly scheduleDevelopment schedule

System evaluation Completed report

System cost 12%Contract maintenance

Research, test systemsupervision

Self-development / ERP additional connectionPQS addition development


System budget

* Total budget : 170M KW

ERP POP

Self-budget 70M KW 100M KW20M KW 48M KWGovernment fund

New soft techniques Co.,Ltd E-sol Co., LtdCorporation

6 month 6 monthDevelopment period

System cost 12% Self- maintenancemaintenance cost

1. the reference of information system build

2. The stability of Development Corporation

3. Price

4. Skill

5. extendable system

6. Developer (project manager)

The point of Selection


Build contents (Improvement of work loss)

Section Loss item

Loss of Sales1. Difficulty of acceptance an order

2. Difficulty of Sale data management

1. The necessary time waste of material requirement planning

2. The accuracy lack of Material receiving

3. The accuracy lack of Material delivery

4. The stock present condition by noteLoss of Quality

Assurance1. The data lack for quality control

2. The data lack for quality improvement

Loss of Purchasing

/Material

1. Difficulty of product history management2. The data lack for Loss goods control 3. Difficulty of productivity management4. The data lack for improvement process

Loss of Production

Inefficient work happed by duplicated work for various documentreportedIssue Point


▣ Information system build story▣

The third chapterInformation system build story

1.1 System configuration1.2 System flow1.3 Operating situation


System configuration

Sales

Preparatory work

Purchasing / Material

Quality assurance

production

Account

assembly parts

Loss /repair

Final test

packaging

ERP Server

POP Server

Job order

Actual production

Connection

(Internet)T1(1.44m)


System flow (integration )

Purchasing /Material

Quality assuranceCustomer Sales Production

3 month

1 weekdemand

forecast Record

demand record

MRP output

MRP request

order

Material orderMaterial delivery

Materialreceive

Material delivery

check

assembly parts

packaging

Actual uploadActual production

record

Check of shipment

Goods receive

Goods deliveryshipment

reservation

Loss/repair

manufacturing planning

Job order

Basic data

MRP Planning

Production Planning

Preparatory work


System flow (ERP)

Production Planning

manufacturing planning

Job order

POP SYSTEM

Point Of Production management

Actual production

Receive order

POP system directly Reflect that connect POP system and ERP system if work order through production

schedule.

ERP↔POP

We can manage POP actual Production by work indication and

do results registration to ERP system, automatic upload during time

Check of shipment


System flow (POP)

Job order

Preparatory work

assembly parts

packaging

POP data ERPdata

Goods receive

ERP↔POP

We can manage POP actual Production by work indication and

do results registration to ERP system, automatic upload during time

Using wireless scanner that receive

PALLET part shipment


Operating situation (POP Process)

Preparatory work

Material ready

Label printing

assembly parts(3POINT)Parts SN

scanning

Process checkGoods SN

scanningJob

order

shipment

Receive PALLET part

Input scanner data

packaging

Parts check

BOX label printing

Loss repair

Loss parts repair

Loss list printing

SHIPMENT


Operating situation (Production field 1)

<Barcode label printing> <Preparatory work>

Image that display bar code label that work direction is attached to production based on ERP

we need in ready work that based on ERP work direction before production injection



< Assembly parts scanning> <Production monitoring>

it is that BOM product and parts serial number scanner for product parts history management

Production progress management is monitoring to model injection provision results.



<Loss repair> <Final test & check>

LOT sample test

PALLET sample test



<Packaging>

It is wrap various manuals and accessory parts with product.

We execute history management by fixing scan in POP system.

After parts check, We print BOX label by last scan process.



<Shipment>

Using data to PALLET Shipment, car history management

Using Wireless scanner

Receive PALLET part

Input scanner data


▣ The Result and expansion direction ▣

The fourth chapterThe Result and expansion direction

4.1 The Result of iThe Result of information system build

4.2 The expansion direction of The expansion direction of Information system build


The Result of iThe Result of information system build (Chart)

2001 2003

Productivity600 EA/day

(8 hour working time)900 EA/day

(8 hour working time)

Input persons 42 persons 53 persons

Productivity/worker 14.3 17.0

Parts loss rate 1% 0.02%

Process Improvement rate 10% 80%

Correct shipment 80% 94%

Documentation of data 4 hour 20 minute

Communication call phone use system

Standard of Documention user's letter system's letter


The Result of iThe Result of information system build (Graph)

Productivity/worker Parts loss rate Process improvement rate

Correct shipment Documentation of data

14.3

17.0

before

after

Result

2001 2003 2001 2003

1.0%0.02%

2001 2003 2001 2003 2001 2003

10%

80% 81%96%

240M

20M

2.7%

0.98%

220M70%

15%


The expansion direction of The expansion direction of Information system build(Master Plan)

The first step (Introduction)

ERP / POPSystem build

Work improvement

Productivity growth

standard ofDocumentation

knowledge management

The third step (Integration)

Groupware

Integration

management innovation

Originalmanagement

The second step (stabilization )

ERP / POPConnection

Qualityimprovement

Correct information

The standard of Production

management

The standard of Quality

management


The expansion direction of The expansion direction of Information system build(Investment Budget)

The first step (Introduction)

2002.06 ~2003.12

Initial investment cost

ERP SW: 70M KW

HW:25M KW

POP SW: 100M KW

HW: 20M KW

The second step (stabilization )

2004.01~2004.12

investment cost

ERP SW:12M KW

POP SW: 10M KW

HW: 35M KW

The third step (Integration)

2005.01~2005.12

investment cost

Groupware

SW:50M KW

management innovation through information system buildppt).pdf 2004-10-28 management innovation...

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