1. Organization chart: Manufacturing Operation Chief ExecutiveOperation FactoryManager ManagerProduction Planning Tester, & ControlverifierProduction Material MaintenanceResearch & Manager Manger & EngineeringDesign Sample, Jig & QC, Tally QC, Inventory Tooling Tools makerAPO TES Bangladesh Furniture Manufacturing 1

2. Material managementFunction- Collect, analize and dessiminate informationabout material utilisation- Preparing the required materials- Determine the current stock level & its value- Ensure the materials is safe in keeping /storageAPO TES Bangladesh Furniture Manufacturing 2 3. Materials controllerHead of department, business ownersManagersExecutives / officersSupervisorsClerks Organisation chart Duties and responsibilityAPO TES Bangladesh Furniture Manufacturing 3 4. Requirement to become materialcontroller 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.APO TES Bangladesh Furniture Manufacturing 4 5. Requirement to become materialcontroller (cont.)Material management: Planning the requirement Purchasing ReceivingMembuat, melapor dan Storagemenyimpan rekod: Maintenence jenis bahan Inventory Kuantiti Releasing for processing nilai DisposingAPO TES Bangladesh Furniture Manufacturing 5 6. Requirement to become material controller (cont.)Material tendency to wear, damage, faulty &depreciateMixing recipeCompatibility of materials to productmanufacturedRate of utilisationAPO TES Bangladesh Furniture Manufacturing 6 7. Materials propertiesPhysical properties: TypeMechanical properties: Maintenance Size Storage Grade Density, chemical content etc. Quality Quantity Value of materials Material usesAPO TES Bangladesh Furniture Manufacturing 7 8. DocumentationMaterial specifications: name, model, physicalpropertiesQuantity: utilization rate daily, weekly, monthlySuppliers: name, address, telephone, productssupplied, terms and pricesPurchasing document: L.O. (purchase order),delivery notes (D.O.), invoicesAPO TES Bangladesh Furniture Manufacturing 8 9. Documentations (cont.)Receiving: goods Inventoryreceived notes Quantity Name Quality Model Production Grade, quality (refer to Material request form specifications) Quantity- Stock cardMaintenance Mechanical PreventiveAPO TES BangladeshFurniture Manufacturing9 10. Raw material managementUnit: Kg., liter, ton, pieces, unit, packing, rolls,drums etc.Safe keeping and safety of materialsReports to superior officers & frequencyNot leaking information to competitorsApplying system: Location, storage methods,replenishKnowing stock levels and utilization rateAPO TES Bangladesh Furniture Manufacturing 10 11. Responsibility of Material Controllers1. 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 checkedRecording the classification changes (if any & allowed) APO TES Bangladesh Furniture Manufacturing 11 12. Responsibility of material controllers2. Rejects materials which doesnt meet specifications Materials used to make the goods Materials quality Quantity Expiry date Non approve buyers / black listed Disapprove brand and modelAPO TES Bangladesh Furniture Manufacturing 12 13. Responsibility of material controllers3. 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 RecordingAPO TES Bangladesh Furniture Manufacturing 13 14. Responsibility of material controllers4. 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 itemsAPO TES Bangladesh Furniture Manufacturing 14 15. Responsibility of material controllers5. 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 valuesAPO TES Bangladesh Furniture Manufacturing 15 16. Responsibility of material controllers (cont.)6. Withdrawing the materials Who can withdraw the materials Written approval Needs according to production schedule Preparing the materials, refer specifications Exact quantity Withdrawal form (materials request forms)APO TES Bangladesh Furniture Manufacturing16 17. Factory management & manufacturing facilities Raw materials Machines andmanufacturing equipmentsBuilding and compound VehichlesAPO TES Bangladesh Furniture Manufacturing 17 18. DefinationsRaw materials Materials use in construction of furniture,processing, assembly, packaging Bahan yang digunakan dalam binaanperabot, pemasangan, pembungkusandan proses pembuatanInventori Mengetahui status dan baki semasaAPO TES Bangladesh Furniture Manufacturing 18 19. Klasifikasi bahan: mengikut sifat fizikal bahan mentah1. Bahan mentah asas: kayu, papan panel2. Bahan mentah pemprosesan: kertas pasir, perekat3. Bahan berbahaya: thinner, minyak4. Hardware: skru, hinges, connectors, aksessori5. Bahan mentah pembungkusan: fabrik, kotak, foam, strap6. Untuk pekerja: ubat, mask, ear plug, glove, measuring tape, caliper7. Mesin: mata alat & alat gantiAPO TES Bangladesh Furniture Manufacturing 19 20. Tempat simpanan bahanBahan tidak disimpan disatutempatMengikut sifat fizikalTempat kegunaan / prosesStruktur keselamatanAPO TES Bangladesh Furniture Manufacturing 20 21. Bahan: kayu gergaji belum dikeringkanAir-dried sawn timber; anisotropicGred:1. Prime 2. Select 3. Standard 4. Sound 5. Serviceable 6. UtilityPenyusunan: a.mengikut spesisb.mengikut saizc.gunakan stickerLantai rata, bersimenKawasan teduh, berbumbungAPO TES Bangladesh Furniture Manufacturing21 22. Bahan mentah: kayu heavyhardwoodsBalau/Selangan Batu (Shorea Keranji (Dialium spp.)spp.) Malagangai (EusideroxylonBalau, Red/Selangan Batu Merahmalagangai) (Shorea spp.)Merbau (Intsia spp.)Belian (Eusideroxylon zwageri)Penaga (Mesua ferrea)Bitis (Madhuca spp. and Penyau (Upuna borneensis)Palaquium spp.) Resak (Vatica spp. andChengal (NeobalanocarpusCotylelobium spp.)heimii) Tembusu (Fagraea spp.)Giam (Hopea spp.)Kekatong (Cynometra spp.)APO TES Bangladesh Furniture Manufacturing22 23. Spesis kayu: medium hardwoodsMengkulang/Kembang (Heritiera spp.)Alan Batu (Shorea albida)Meransi (Carallia spp.)Bekak (Amoora spp.)Merawan / Gagil (Hopea spp.)Derum (Cratoxylum spp.)Merbatu (Parinari spp. and Maranthes corymbosa)Entapuloh (Teijsmanniodendron spp.)Merpauh (Swintonia spp.)Geriting / Teruntum (Lumnitzera spp.)Mertas (Ctenolophon parvifolius)Kandis (Garcinia spp.)Nyalin (Xanthophyllum spp.)Kapur (Dryobalanops spp.)Pauh Kijang (Irvingia malayana)Kasai (Pometia spp.)Perah (Elateriospermum tapos)Kayu Malam (Diospyros spp.)Petaling (Ochanostachys amentacea)Kedang Belum/Tulang Daing (Milletia spp.)Punah (Tetramerista glabra)Kelat (Eugenia spp.)Ranggu (Koordersiodendron pinnatum)Keledang (Artocarpus spp.)Rengas (Gluta spp. and Melanochyla spp.)Kempas (Koompassia malaccensis)Semayur (Shorea inaequilateralis)Keruing (Dipterocarpus spp.)Senumpul (Hydnocarpus spp.)Keruntum (Combretocarpus rotundatus)Simpoh (Dillenia spp.)Kulim (Scorodocarpus borneensis)Tampoi (Baccaurea spp.)Mata Ulat (Kokoona spp.)Tualang (Koompassia excelsa)Mempening (Lithocarpus spp. and Quercus spp.) APO TES BangladeshFurniture Manufacturing 23 24. Spesis kayu: light hardwoodAlan Bunga (Shorea albida)Ara (Ficus spp.)Mempisang / Karai (Species of Annonaceae)Babai (Saraca spp.) Meranti Bakau (Shorea uliginosa)Bayur (Pterospermum spp.) Meranti, Dark Red/Obar Suluk (Shorea spp.)Berangan (Castanopsis spp.) Meranti, Light Red/Red Seraya (Shorea spp.)Bintangor (Calophyllum spp.)Meranti, White/Melapi (Shorea spp.)Binuang (Octomeles sumatrana) Meranti, Yellow/Yellow Seraya (Shorea spp.)Dedali (Strombosia javanica)Merbulan (Blumeodendron spp.)Durian (Coelostegia spp., Durio spp. and Neesia Mersawa (Anisoptera spp.)spp.) Nyatoh (Species of Sapotaceae)Geronggang/Serungan (Cratoxylum spp.) Pelajau (Pentaspadon spp.)Gerutu (Parashorea spp.)Penarahan (Species of Myristicaceae)Jelutong (Dyera spp.) Perupok (Lophopetalum spp.)Jongkong (Dactylocladus stenostachys) Petai (Parkia spp.)Kedondong (Species of Burseraceae)Pulai (Alstonia spp.)Kelumpang (Sterculia spp.)Ramin (Gonystylus spp.)Kembang Semangkok (Scaphium spp.) Malaysian oak (Hevea brasiliensis)Ketapang (Terminalia spp.)Sengkuang (Dracontomelum dao)Kungkur (Pithecellobium spp.) Sentang (Azadirachta excelsa)Laran (Anthocephalus chinensis) Sepetir (Sindora spp. and Copaifera palustris)Machang (Mangifera spp.)Sesendok (Endospermum spp.)Mahang (Macaranga spp.) Terap (Artocarpus spp., Paratocarpus spp. andMedang (Species of Lauraceae) Antiaris toxicaria)Melantai / Kawang (Shorea spp.) Terentang (Campnosperma spp.)Melunak (Pentace spp.)White Seraya (Parashorea spp.) APO TES Bangladesh Furniture Manufacturing24 25. Sifir industri kayu Sawn timberContoh, diberi:1 cu. ft. = 0.0283186 M3 2.25 x 3.5 x 8 ada 125 batang Kirakan ton kayu?1 ton = 50cu.ft.= 1.41584 M3 (l x t x p)/(12 x 12 x 50) x unit1 M3 = 0.7063 ton= 2.25 x 3.5 x 8 /(7200)x 125 = 1.09375 ton APO TES Bangladesh Furniture Manufacturing 25 26. Pengiraan M3 kayu Contoh: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 ft3ft.3 = M3172835.31 56.8749 ft.3 =1.610733 M3Nota:35.311728 = 12 x 12 x 12 56.8749 ft.3 = 1.1375 ton35.31 =5050 1.41584APO TES Bangladesh Furniture Manufacturing 26 27. Bahan: kayu gergaji sudah dikeringkanKandungan lembapan: _ % MCKandungan lembapan keseimbangan: 12 13 % EMCSusunan: closed stack (tiada stickers)Bundled: sama spesis & saiz, panjang yangsama, sapu cat/lilin dihujung, bungkusdengan plastik, gunakan alas sama jarak, 4Kawasan teduh, bersimen, rata,berbumbung, berdindingAPO TES Bangladesh Furniture Manufacturing 27 28. Bahan: kayu berketamDiketam dan dipotong kepada saiz akhirMempunyai MC% yang dikehendakiBundled: sama spesis, sama saiz, dibungkusSimpanan: kawasan teduh, bersimen, rata,berdindingJauh dari dingin/panas: perubahan cuaca bengkok, berbulu dan mengembangUkuran: M3APO TES Bangladesh Furniture Manufacturing 28 29. Bahan: mouldingsKayu berprofilContoh: frame, splint, skirting, jamb etc.Bundled: sama spesis, sama profil, sama saiz,dibungkus plastik, ikat.Susun dalam crateUkuran: ft. run, mrAPO TES Bangladesh Furniture Manufacturing 29 30. Bahan: komponen perabotContoh: turnings, kaki, tops dll.Berbagai bentuk, saiz dan warnaFinished & unfinishedDisusun, dibungkus & diletak ditempat teduhJangan simpan > 4 bulan (kayu); akan hilangketepatan saiz, profilAPO TES Bangladesh Furniture Manufacturing 30 31. Bahan: papan panelPapan lapisBinaan: lapisan venir berperekat disusun ira berselang selidalam bilangan ganjilPerekat: urea formaldehyde (MR moisture resistance) &phenol formaldehyde (WBP water boiling proof)Gred: face back; AA, BB, CCValue added: laminated face tego filmSusunan: jenis perekat, gred, saiz, dibungkus, kawasanteduhKayu penggalas: sama saiz, jarak 2, 6 dari hujungAPO TES Bangladesh Furniture Manufacturing31 32. Bahan: papan panel lainFiberboard (MDF, HDF)ChipboardSoftboardParticleboard- Binaan: habuk/serbuk/serpai kayu, berbagai saiz, digaul denganperekat- Ukuran: ketumpatan, saiz (4x8,6x8,3x6)- Gred: mengikut pelepasan formaldehyde; E0, E1, E2, E3- Susunan: mengikut jenis, saiz, gred, kawasan teduh, dibungkusplastik- Kayu pengalas: sama saiz, jarak 2APO TES Bangladesh Furniture Manufacturing 32 33. Bahan: pelapik mukaFormica, MaicaAicaHigh pressure laminate (HPL); Post forming,soft forming- Backing: kertas, plastik, venir- Perekat: contact glue- Susunan: mengikut jenis, saiz, dibungkus- Suhu: terkawal; < 24CAPO TES Bangladesh Furniture Manufacturing 33 34. Bahan: kertas pasirJenis: granit, kaca, silicaGred: paling kasar (00), halus (480)Backing: kertas, kain, plastikPerekat: contact glue, proteinKegunaan: mempelas, kemasiapanBentuk: mengikut mesin; sheet, wide belt, disc, longbeltSimpanan: bilik hawa panas (30C -35C; guna lampu15 watt)Susunan: kepingan (disusun), gulungan (digantung)APO TES Bangladesh Furniture Manufacturing 34 35. Bahan: perekatWater-based, oil-basedPVAC, urea formaldehyde, contact glue, glukosa, hotmelt glue, protein, super glue etc.Hardener, retarderShelve life: sebelum campur hardenerPot life: selepas campur hardenerStandard guna: kelikatan (viscosity)Bekas: bersih, tiada benda asing, bekas khas, kuantitistandard i.e. 20kg, 18LBilik: suhu sejuk < 20C; superglue (peti sejuk)APO TES Bangladesh Furniture Manufacturing 35 36. Bahan: minyakKenderaan: petrol, diesel, cylinder, coolant,transmissionMesin: grease, hydraulicGred: SAE (kelikatan)Ukuran: literBekas khas: kedap udara, tiada benda asing,jauh dari bangunan awamBilik sejuk (< 18C), bawah tanahAPO TES Bangladesh Furniture Manufacturing 36 37. Bahan: kemasiapanNitro cellulose (NC), acid catalyzed (AC), poly urethane(PU), cat, varnish, minyakUkuran kekuatan: resin content, solid contentKualiti: hardness, durability, kilauanBahan lebur: thinner, air; retarderShelf life; pot lifeMudah terbakar, terpeluapBekas khas: kedap udara, jauh dari bangunan awamSuhu simpanan: sejuk (< 28C)APO TES Bangladesh Furniture Manufacturing 37 38. Bahan: pengikatSkru, paku, bolt & nut, staples, minifixSpesifikasi: panjang, diameter, bentuk kepala,bahagian pemutar, bentuk hujung, saduran,warnaRosak: karat, berubah warnaBungkus: plastik, spesifikasi, kuantiti mudahBekas: kotakStor utamaAPO TES Bangladesh Furniture Manufacturing 38 39. Bahan: penyambungHinges, connector, catchesSpesifikasi: tempat kegunaan, saiz, model #,warnaRosak: karat, gagal berfungsi dengan elokBungkus: mengikut model, plastik, kuantitimudahBekas: kotakStor utamaAPO TES Bangladesh Furniture Manufacturing 39 40. Bahan: aksessori perabotTombol laci/pintu, kunci, drawer slide, toe kick,stopperSpesifikasi: kegunaan, saiz, warna, modelRosak: lusuh, karat, gagal berfungsiBungkus: mengikut model, kuantiti mudahBekas: kotakStor utamaAPO TES Bangladesh Furniture Manufacturing 40 41. Bahan: aksessori berasaskan plastikScrew caps, slides, adjuster, paddingSpesifikasi: saiz, warna, modelBungkus: plastik, kuantiti mudahSuhu: kurang dari suhu bilik (< 28C)Bekas: kotakStor utamaAPO TES Bangladesh Furniture Manufacturing 41 42. Bahan: fabrik & kulitKainBahan: kapas, polyester, wool etc.Mengikut bentuk tenunanSpesifikasi: bahan asas, warna, lebar,ketahanan, modelBungkus: gulung (roll), baring, kayu / kodiKulitStor: kering, suhu > 28CAPO TES Bangladesh Furniture Manufacturing 42 43. Bahan: pembungkusanKotak, PU foam, plastik wrapper, strapAssembly instruction sheet, write upKotak di pipihkan, ikatDibungkus, bahan tidak jadi lusuhStor: kering, suhu > 32CAPO TES Bangladesh Furniture Manufacturing 43 44. Bahan: keselamatan pekerjaDusk mask, ear plug, gloves, safety shoesPakaian seragam, apronDibungkus plastikdiikat dalam kuantiti mudahStor utama, keringAPO TES Bangladesh Furniture Manufacturing 44 45. Bahan: alatan pengukuranMeasuring tapes, veneer caliper, gauges,moisture meterSimpan keringStor utamaAPO TES Bangladesh Furniture Manufacturing 45 46. Bahan: toolsAlatan tangan: screw driver, pliers, spanner,tukul besi, wrenchesSimpan: kuantiti mudahStor utamaAPO TES Bangladesh Furniture Manufacturing 46 47. Bahan: mesin toolingKnives blade, profile knives, circular saw, bandsaw, drill bits, router bitsDisusun atas rak, kotak panelMudah karatSenggaraan: sapu minyakStor mesinAPO TES Bangladesh Furniture Manufacturing 47 48. Bahan: senggaraanKunci: peti kunciTanggaAlatan elektrik: mentol, volt meter, wireStor sengaraanAPO TES Bangladesh Furniture Manufacturing 48 49. Mesin kecilJig saw, hand router, hand trimmer, drill,screw driver dll.: elektrik & air poweredDiberi nombor rujukan unik bagi setiap satuNama pengguna dicatitkan mengikut tarikh &waktuDisimpan dalam setor alatDipasang mata & diuji sebelum dan selepasdikeluarkan dari setorAPO TES Bangladesh Furniture Manufacturing 49 50. Peralatan semburanKemasiapan: spray gun, hos, pump, tangki dll.Perekatan: spray gun, hos dll.Dibersihkan selepas digunakanDiberi nombor rujukan unikDisimpan di setor semburanRekodkan nama penggunaAPO TES Bangladesh Furniture Manufacturing 50 51. Mesin tetapX-cut saw, rip saw, moulder, panel saw, router,drill, sander, air compressor etc.Bekalan elektrik betul & pendawaian selamatAlat keselamatan & tooling terkawalTerlindung dari cuaca yang melampauMesin diikat dilantai rata dengan kukuhDiberi nombor rujukan unikAda jadual senggaraanNama operator / senggaraAPO TES Bangladesh Furniture Manufacturing 51 52. Peralatan kilangDust extractor, silo, piping, spray booth,conveyor, hoist, work bench, perabot dll.Ditempatkan / melalui kawasan yangselamat.Ditanda dengan kod warnaDiperiksa / dibersihkan secara berjadualAPO TES Bangladesh Furniture Manufacturing 52 53. Kenderaan & handling equipmentPallet truck, forklift, roller conveyor, lori,van, kereta dll.Disimpan ditempat yang dikhaskanDisenggara mengikut jadualOperator yang dibenarkan sahajaAPO TES Bangladesh Furniture Manufacturing 53 54. Bangunan & kawasanBangunan, pondok, tempat letakkenderaan, pagar, parit, tangki kumbahan,taman, pintu, tingkap, tangga dll.Tiada yang tersumbat, kotor, tidak terjagaTiada tempat pembiakanMenugaskan anggota khusus untukmenjaga kawasan dan bangunanHarta benda selamat & terkawalAPO TES Bangladesh Furniture Manufacturing 54 55. TQM: Concept - TPM5 Ss 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 - disciplineAPO TES Bangladesh Furniture Manufacturing 55 56. TQM: Concept - TPM 5 Cs of Good Housekeeping1) Clean out - determine what is necessary &unnecessary & dispose of the latter2) Configure - provide a convenient, safe & orderlyplace for everything & keep it there3) Clean & check - monitor the condition of the areaduring cleaning4) Conformity - develop the habit of routinelymaintaining cleanliness5) Custom & practice - train people in the disciplines ofthe 5CsAPO TES Bangladesh Furniture Manufacturing 56 57. 5 S (Bahasa Malaysia)SisihSusunSapuSelia / SeragamSentiasa amalAPO TES Bangladesh Furniture Manufacturing 57 58. 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 suasanaAPO TES Bangladesh Furniture Manufacturing 58 59. TQM: Konsep - TPM Step 1(what does the company require?)Step 5 Step 2(educate people (is everythingabout the rules) in order?) Step 4 Step 3(keep clean)(clean up)APO TES Bangladesh Furniture Manufacturing 59 60. TQM: Konsep - TPMSasaran 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 kecilAPO TES Bangladesh Furniture Manufacturing 60 61. TQM: Konsep - TPM5 aktiviti pembangunan TPM: 1) Menghapuskan 6 punca kerugian utama(slide berikut) untuk memanjang hayatperalatan. 2) Program senggaraan yang bebas 3) Program senggaraan terancang 4) Meningkatkan kemahiran anggota operasi &senggaraan 5) Program pengurusan peralatan asasAPO TES Bangladesh Furniture Manufacturing 61 62. TQM: Konsep - TPMFokus TPM keatas 6 punca utamakerugian peralatan 1) Peralatan tidak berfungsi 2) Set-up & adjustment time 3) idling & minor stoppages 4) Mengurankan kelajuan 5) Kecacatan proses 6) Mengurangkan hasil perolehanKumpulan kecil yang bebas fokus kepada6 punca utama kerugianAPO TES Bangladesh Furniture Manufacturing 62 63. Kita tangguhkan dulu.APO TES Bangladesh Furniture Manufacturing 63