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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
  APO TES Bangladesh             Furniture Manufacturing             1
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



APO TES Bangladesh   Furniture Manufacturing   2
Materials controller
  Head of department, business owners
  Managers
  Executives / officers
  Supervisors
  Clerks

 Organisation chart
 Duties and responsibility

APO TES Bangladesh   Furniture Manufacturing   3
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.

APO TES Bangladesh   Furniture Manufacturing   4
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


APO TES Bangladesh   Furniture Manufacturing   5
Requirement to become material
         controller (cont.)
  Material tendency to wear, damage, faulty &
  depreciate
  Mixing recipe
  Compatibility of materials to product
  manufactured
  Rate of utilisation




APO TES Bangladesh   Furniture Manufacturing   6
Materials properties
  Physical properties:
   
       Type
                                    Mechanical properties:
                                        Maintenance
      Size
                                        Storage
      Grade
      Density, chemical
       content etc.
      Quality
   
       Quantity
   
       Value of materials
      Material uses

APO TES Bangladesh   Furniture Manufacturing     7
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




APO TES Bangladesh   Furniture Manufacturing   8
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

APO TES Bangladesh    Furniture Manufacturing          9
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


APO TES Bangladesh   Furniture Manufacturing   10
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)




 APO TES Bangladesh   Furniture Manufacturing   11
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



APO TES Bangladesh   Furniture Manufacturing   12
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




APO TES Bangladesh   Furniture Manufacturing   13
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


APO TES Bangladesh   Furniture Manufacturing   14
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



APO TES Bangladesh   Furniture Manufacturing   15
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 Manufacturing    16
Factory management &
           manufacturing facilities

       Raw materials                           Machines and
                                                manufacturing
                                                 equipments




  Building and compound                         Vehichles




APO TES Bangladesh   Furniture Manufacturing         17
Definations
  Raw materials
 Materials use in construction of furniture,
  processing, assembly, packaging
 Bahan yang digunakan dalam binaan
  perabot, pemasangan, pembungkusan
  dan proses pembuatan

  Inventori
 Mengetahui status dan baki semasa

APO TES Bangladesh   Furniture Manufacturing   18
Klasifikasi bahan: mengikut sifat
           fizikal bahan mentah
1. Bahan mentah asas: kayu, papan panel
2. Bahan mentah pemprosesan: kertas pasir, perekat
3. Bahan berbahaya: thinner, minyak
4. Hardware: skru, hinges, connectors, aksessori
5. Bahan mentah pembungkusan: fabrik, kotak, foam,
   strap
6. Untuk pekerja: ubat, mask, ear plug, glove,
   measuring tape, caliper
7. Mesin: mata alat & alat ganti



APO TES Bangladesh   Furniture Manufacturing   19
Tempat simpanan bahan
  Bahan tidak disimpan disatu
  tempat
  Mengikut sifat fizikal
  Tempat kegunaan / proses
  Struktur keselamatan




APO TES Bangladesh   Furniture Manufacturing   20
Bahan: kayu gergaji belum
               dikeringkan
    Air-dried sawn timber; anisotropic
    Gred:        1.     Prime
                 2.     Select
                 3.     Standard
                 4.     Sound
                 5.     Serviceable
                 6.     Utility
    Penyusunan:         a.      mengikut spesis
                        b.      mengikut saiz
                        c.      gunakan sticker
    Lantai rata, bersimen
    Kawasan teduh, berbumbung
APO TES Bangladesh   Furniture Manufacturing      21
Bahan mentah: kayu – heavy
            hardwoods
  Balau/Selangan Batu (Shorea         Keranji (Dialium spp.)
  spp.)                               Malagangai (Eusideroxylon
  Balau, Red/Selangan Batu Merah      malagangai)
   (Shorea spp.)                      Merbau (Intsia spp.)
  Belian (Eusideroxylon zwageri)      Penaga (Mesua ferrea)
  Bitis (Madhuca spp. and             Penyau (Upuna borneensis)
  Palaquium spp.)                     Resak (Vatica spp. and
  Chengal (Neobalanocarpus            Cotylelobium spp.)
  heimii)                             Tembusu (Fagraea spp.)
  Giam (Hopea spp.)
  Kekatong (Cynometra spp.)




APO TES Bangladesh   Furniture Manufacturing      22
Spesis kayu: medium hardwoods
                                            Mengkulang/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 Bangladesh          Furniture Manufacturing               23
Spesis kayu: light hardwood
Alan 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. and
Medang (Species of Lauraceae)                         Antiaris toxicaria)
Melantai / Kawang (Shorea spp.)                   Terentang (Campnosperma spp.)
Melunak (Pentace spp.)                            White Seraya (Parashorea spp.)
   APO TES Bangladesh               Furniture Manufacturing                24
Sifir industri kayu
   Sawn timber                        Contoh, 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 unit

1 M3 = 0.7063 ton                  = 2.25 x 3.5 x 8 /(7200)x 125

                                   = 1.09375 ton




 APO TES Bangladesh     Furniture Manufacturing       25
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 ft3
ft.3               = M3              1728
35.31
                                     56.8749 ft.3 =1.610733 M3
Nota:                                35.31
1728 = 12 x 12 x 12
                                     56.8749 ft.3 = 1.1375 ton
35.31 =            50                50
                   1.41584



  APO TES Bangladesh         Furniture Manufacturing       26
Bahan: kayu gergaji sudah
               dikeringkan
  Kandungan lembapan: _ % MC
  Kandungan lembapan keseimbangan: 12 –
  13 % EMC
  Susunan: closed stack (tiada stickers)
  Bundled: sama spesis & saiz, panjang yang
  sama, sapu cat/lilin dihujung, bungkus
  dengan plastik, gunakan alas sama jarak, 4’
  Kawasan teduh, bersimen, rata,
  berbumbung, berdinding

APO TES Bangladesh   Furniture Manufacturing   27
Bahan: kayu berketam
  Diketam dan dipotong kepada saiz akhir
  Mempunyai MC% yang dikehendaki
  Bundled: sama spesis, sama saiz, dibungkus
  Simpanan: kawasan teduh, bersimen, rata,
  berdinding
  Jauh dari dingin/panas: perubahan cuaca –
  bengkok, berbulu dan mengembang
  Ukuran: M3



APO TES Bangladesh   Furniture Manufacturing   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




APO TES Bangladesh   Furniture Manufacturing   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




APO TES Bangladesh   Furniture Manufacturing   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



APO TES Bangladesh   Furniture Manufacturing    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’



APO TES Bangladesh     Furniture Manufacturing       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


APO TES Bangladesh   Furniture Manufacturing   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)

APO TES Bangladesh   Furniture Manufacturing   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)

APO TES Bangladesh   Furniture Manufacturing   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


APO TES Bangladesh   Furniture Manufacturing   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)


APO TES Bangladesh   Furniture Manufacturing   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


APO TES Bangladesh   Furniture Manufacturing   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


APO TES Bangladesh   Furniture Manufacturing   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



APO TES Bangladesh   Furniture Manufacturing   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




APO TES Bangladesh   Furniture Manufacturing   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


APO TES Bangladesh   Furniture Manufacturing   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




APO TES Bangladesh   Furniture Manufacturing   43
Bahan: keselamatan pekerja
  Dusk mask, ear plug, gloves, safety shoes
  Pakaian seragam, apron
  Dibungkus plastik
  diikat dalam kuantiti mudah
  Stor utama, kering




APO TES Bangladesh   Furniture Manufacturing   44
Bahan: alatan pengukuran
  Measuring tapes, veneer caliper, gauges,
  moisture meter
  Simpan kering
  Stor utama




APO TES Bangladesh   Furniture Manufacturing   45
Bahan: tools
  Alatan tangan: screw driver, pliers, spanner,
  tukul besi, wrenches
  Simpan: kuantiti mudah
  Stor utama




APO TES Bangladesh   Furniture Manufacturing   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




APO TES Bangladesh   Furniture Manufacturing   47
Bahan: senggaraan
  Kunci: peti kunci
  Tangga
  Alatan elektrik: mentol, volt meter, wire
  Stor sengaraan




APO TES Bangladesh   Furniture Manufacturing   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


APO TES Bangladesh   Furniture Manufacturing   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




APO TES Bangladesh   Furniture Manufacturing   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


APO TES Bangladesh   Furniture Manufacturing   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



APO TES Bangladesh   Furniture Manufacturing   52
Kenderaan & handling equipment
  Pallet truck, forklift, roller conveyor, lori,
  van, kereta dll.
  Disimpan ditempat yang dikhaskan
  Disenggara mengikut jadual
  Operator yang dibenarkan sahaja




APO TES Bangladesh   Furniture Manufacturing   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
APO TES Bangladesh   Furniture Manufacturing   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




APO TES Bangladesh   Furniture Manufacturing   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


APO TES Bangladesh   Furniture Manufacturing   56
5 S (Bahasa Malaysia)
  Sisih
  Susun
  Sapu
  Selia / Seragam
  Sentiasa amal




APO TES Bangladesh   Furniture Manufacturing   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

APO TES Bangladesh   Furniture Manufacturing   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)
APO TES Bangladesh   Furniture Manufacturing     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   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
APO TES Bangladesh   Furniture Manufacturing   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
APO TES Bangladesh   Furniture Manufacturing   62
Kita tangguhkan dulu.




APO TES Bangladesh   Furniture Manufacturing   63

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Mat mgt

  • 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 APO TES Bangladesh Furniture Manufacturing 1
  • 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 APO TES Bangladesh Furniture Manufacturing 2
  • 3. Materials controller Head of department, business owners Managers Executives / officers Supervisors Clerks  Organisation chart  Duties and responsibility APO TES Bangladesh Furniture Manufacturing 3
  • 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. APO TES Bangladesh Furniture Manufacturing 4
  • 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 APO TES Bangladesh Furniture Manufacturing 5
  • 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 APO TES Bangladesh Furniture Manufacturing 6
  • 7. Materials properties Physical properties:  Type Mechanical properties:  Maintenance  Size  Storage  Grade  Density, chemical content etc.  Quality  Quantity  Value of materials  Material uses APO TES Bangladesh Furniture Manufacturing 7
  • 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 APO TES Bangladesh Furniture Manufacturing 8
  • 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 APO TES Bangladesh Furniture Manufacturing 9
  • 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 APO TES Bangladesh Furniture Manufacturing 10
  • 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) APO TES Bangladesh Furniture Manufacturing 11
  • 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 APO TES Bangladesh Furniture Manufacturing 12
  • 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 APO TES Bangladesh Furniture Manufacturing 13
  • 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 APO TES Bangladesh Furniture Manufacturing 14
  • 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 APO 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 Manufacturing 16
  • 17. Factory management & manufacturing facilities Raw materials Machines and manufacturing equipments Building and compound Vehichles APO TES Bangladesh Furniture Manufacturing 17
  • 18. Definations Raw materials  Materials use in construction of furniture, processing, assembly, packaging  Bahan yang digunakan dalam binaan perabot, pemasangan, pembungkusan dan proses pembuatan Inventori  Mengetahui status dan baki semasa APO TES Bangladesh Furniture Manufacturing 18
  • 19. Klasifikasi bahan: mengikut sifat fizikal bahan mentah 1. Bahan mentah asas: kayu, papan panel 2. Bahan mentah pemprosesan: kertas pasir, perekat 3. Bahan berbahaya: thinner, minyak 4. Hardware: skru, hinges, connectors, aksessori 5. Bahan mentah pembungkusan: fabrik, kotak, foam, strap 6. Untuk pekerja: ubat, mask, ear plug, glove, measuring tape, caliper 7. Mesin: mata alat & alat ganti APO TES Bangladesh Furniture Manufacturing 19
  • 20. Tempat simpanan bahan Bahan tidak disimpan disatu tempat Mengikut sifat fizikal Tempat kegunaan / proses Struktur keselamatan APO TES Bangladesh Furniture Manufacturing 20
  • 21. Bahan: kayu gergaji belum dikeringkan Air-dried sawn timber; anisotropic Gred: 1. Prime 2. Select 3. Standard 4. Sound 5. Serviceable 6. Utility Penyusunan: a. mengikut spesis b. mengikut saiz c. gunakan sticker Lantai rata, bersimen Kawasan teduh, berbumbung APO TES Bangladesh Furniture Manufacturing 21
  • 22. Bahan mentah: kayu – heavy hardwoods Balau/Selangan Batu (Shorea Keranji (Dialium spp.) spp.) Malagangai (Eusideroxylon Balau, Red/Selangan Batu Merah malagangai) (Shorea spp.) Merbau (Intsia spp.) Belian (Eusideroxylon zwageri) Penaga (Mesua ferrea) Bitis (Madhuca spp. and Penyau (Upuna borneensis) Palaquium spp.) Resak (Vatica spp. and Chengal (Neobalanocarpus Cotylelobium spp.) heimii) Tembusu (Fagraea spp.) Giam (Hopea spp.) Kekatong (Cynometra spp.) APO TES Bangladesh Furniture Manufacturing 22
  • 23. Spesis kayu: medium hardwoods Mengkulang/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 Bangladesh Furniture Manufacturing 23
  • 24. Spesis kayu: light hardwood Alan 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. and Medang (Species of Lauraceae) Antiaris toxicaria) Melantai / Kawang (Shorea spp.) Terentang (Campnosperma spp.) Melunak (Pentace spp.) White Seraya (Parashorea spp.) APO TES Bangladesh Furniture Manufacturing 24
  • 25. Sifir industri kayu Sawn timber Contoh, 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 unit 1 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 ft3 ft.3 = M3 1728 35.31 56.8749 ft.3 =1.610733 M3 Nota: 35.31 1728 = 12 x 12 x 12 56.8749 ft.3 = 1.1375 ton 35.31 = 50 50 1.41584 APO TES Bangladesh Furniture Manufacturing 26
  • 27. Bahan: kayu gergaji sudah dikeringkan Kandungan lembapan: _ % MC Kandungan lembapan keseimbangan: 12 – 13 % EMC Susunan: closed stack (tiada stickers) Bundled: sama spesis & saiz, panjang yang sama, sapu cat/lilin dihujung, bungkus dengan plastik, gunakan alas sama jarak, 4’ Kawasan teduh, bersimen, rata, berbumbung, berdinding APO TES Bangladesh Furniture Manufacturing 27
  • 28. Bahan: kayu berketam Diketam dan dipotong kepada saiz akhir Mempunyai MC% yang dikehendaki Bundled: sama spesis, sama saiz, dibungkus Simpanan: kawasan teduh, bersimen, rata, berdinding Jauh dari dingin/panas: perubahan cuaca – bengkok, berbulu dan mengembang Ukuran: M3 APO TES Bangladesh Furniture Manufacturing 28
  • 29. 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 APO TES Bangladesh Furniture Manufacturing 29
  • 30. 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 APO TES Bangladesh Furniture Manufacturing 30
  • 31. 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 APO TES Bangladesh Furniture Manufacturing 31
  • 32. 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’ APO TES Bangladesh Furniture Manufacturing 32
  • 33. 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 APO TES Bangladesh Furniture Manufacturing 33
  • 34. 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) APO TES Bangladesh Furniture Manufacturing 34
  • 35. 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) APO TES Bangladesh Furniture Manufacturing 35
  • 36. 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 APO TES Bangladesh Furniture Manufacturing 36
  • 37. 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) APO TES Bangladesh Furniture Manufacturing 37
  • 38. 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 APO TES Bangladesh Furniture Manufacturing 38
  • 39. 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 APO TES Bangladesh Furniture Manufacturing 39
  • 40. 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 APO TES Bangladesh Furniture Manufacturing 40
  • 41. 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 APO TES Bangladesh Furniture Manufacturing 41
  • 42. 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 APO TES Bangladesh Furniture Manufacturing 42
  • 43. 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 APO TES Bangladesh Furniture Manufacturing 43
  • 44. Bahan: keselamatan pekerja Dusk mask, ear plug, gloves, safety shoes Pakaian seragam, apron Dibungkus plastik diikat dalam kuantiti mudah Stor utama, kering APO TES Bangladesh Furniture Manufacturing 44
  • 45. Bahan: alatan pengukuran Measuring tapes, veneer caliper, gauges, moisture meter Simpan kering Stor utama APO TES Bangladesh Furniture Manufacturing 45
  • 46. Bahan: tools Alatan tangan: screw driver, pliers, spanner, tukul besi, wrenches Simpan: kuantiti mudah Stor utama APO TES Bangladesh Furniture Manufacturing 46
  • 47. 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 APO TES Bangladesh Furniture Manufacturing 47
  • 48. Bahan: senggaraan Kunci: peti kunci Tangga Alatan elektrik: mentol, volt meter, wire Stor sengaraan APO TES Bangladesh Furniture Manufacturing 48
  • 49. 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 APO TES Bangladesh Furniture Manufacturing 49
  • 50. 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 APO TES Bangladesh Furniture Manufacturing 50
  • 51. 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 APO TES Bangladesh Furniture Manufacturing 51
  • 52. 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 APO TES Bangladesh Furniture Manufacturing 52
  • 53. Kenderaan & handling equipment Pallet truck, forklift, roller conveyor, lori, van, kereta dll. Disimpan ditempat yang dikhaskan Disenggara mengikut jadual Operator yang dibenarkan sahaja APO TES Bangladesh Furniture Manufacturing 53
  • 54. 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 APO TES Bangladesh Furniture Manufacturing 54
  • 55. 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 APO TES Bangladesh Furniture Manufacturing 55
  • 56. 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 APO TES Bangladesh Furniture Manufacturing 56
  • 57. 5 S (Bahasa Malaysia) Sisih Susun Sapu Selia / Seragam Sentiasa amal APO 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 suasana APO TES Bangladesh Furniture Manufacturing 58
  • 59. 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) APO TES Bangladesh Furniture Manufacturing 59
  • 60. 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 60
  • 61. 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 APO TES Bangladesh Furniture Manufacturing 61
  • 62. 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 APO TES Bangladesh Furniture Manufacturing 62
  • 63. Kita tangguhkan dulu. APO TES Bangladesh Furniture Manufacturing 63