International Technology Transfer Management Industrial Engineering Dr. rer. nat. Dieter Lubkoll Wintersemester 2003/2004 Lecture Notes by Phillip Kern ___________________________________________________________________ Industrial Engineering 1 LITERATURE ................................................................................................................. 2 2 CASE STUDY 1 ................................................................................................................ 2 3 DEFINITIONS ................................................................................................................. 3 3.1 INDUSTRIAL ORGANIZATION ....................................................................................... 3 3.2 SYSTEMATIC OF INDUSTRIAL ENGINEERING ................................................................ 4 3.3 FUNCTIONS OF IE IN ENTERPRISES .............................................................................. 5 4 DOCUMENTATION OF A PRODUCT ........................................................................ 5 5 ROUTING PLAN / MASTER ROUTE SHEET (FERTIGUNGSPLAN) ................... 6 5.1 BUILDING OF ROUTING................................................................................................. 7 6 CASE STUDY 2 ................................................................................................................ 9 6.1 CREATE A TEAM CHART FOR THIS TEAM .................................................................... 10 6.2 WHICH PRODUCT DOCUMENTATIONS ARE NEEDED FOR THE TRANSFER? ................... 11 6.3 DEFINE THE POTENTIAL STEPS FOR THE TRANSFER .................................................... 11 6.4 DEFINE A MILESTONE PLAN FOR THE TRANSFER ........................................................ 11 6.5 TRANSFER OF SPECIAL EQUIPMENT AND FIXTURES TO SIGNA .................................... 11 7 METHODS TO FIND OUT STANDARD TIMES ..................................................... 12 7.1 STANDARD COST CALCULATION ................................................................................ 13 8 WORK ORGANIZATION............................................................................................ 14 8.1 DIRECT DEPARTMENTS............................................................................................... 14 8.2 INDIRECT DEPARTMENTS ........................................................................................... 23 9 MATERIAL MANAGEMENT..................................................................................... 24 10 ORDER PROCESSING AND PRODUCTION PLANNING & CONTROL (PPC)26 10.1 TASKS, OBJECTIVES AND DEFINITION OF PPC........................................................... 26 1/35
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
1 LITERATURE ................................................................................................................. 2
2 CASE STUDY 1................................................................................................................ 2
3 DEFINITIONS ................................................................................................................. 3 3.1 INDUSTRIAL ORGANIZATION ....................................................................................... 3 3.2 SYSTEMATIC OF INDUSTRIAL ENGINEERING................................................................ 4 3.3 FUNCTIONS OF IE IN ENTERPRISES .............................................................................. 5
4 DOCUMENTATION OF A PRODUCT........................................................................ 5
5 ROUTING PLAN / MASTER ROUTE SHEET (FERTIGUNGSPLAN) ................... 6 5.1 BUILDING OF ROUTING................................................................................................. 7
6 CASE STUDY 2................................................................................................................ 9 6.1 CREATE A TEAM CHART FOR THIS TEAM .................................................................... 10 6.2 WHICH PRODUCT DOCUMENTATIONS ARE NEEDED FOR THE TRANSFER? ................... 11 6.3 DEFINE THE POTENTIAL STEPS FOR THE TRANSFER .................................................... 11 6.4 DEFINE A MILESTONE PLAN FOR THE TRANSFER ........................................................ 11 6.5 TRANSFER OF SPECIAL EQUIPMENT AND FIXTURES TO SIGNA .................................... 11
7 METHODS TO FIND OUT STANDARD TIMES ..................................................... 12
7.1 STANDARD COST CALCULATION ................................................................................ 13
8 WORK ORGANIZATION............................................................................................ 14 8.1 DIRECT DEPARTMENTS............................................................................................... 14 8.2 INDIRECT DEPARTMENTS ........................................................................................... 23
9 MATERIAL MANAGEMENT..................................................................................... 24
10 ORDER PROCESSING AND PRODUCTION PLANNING & CONTROL (PPC)26 10.1 TASKS, OBJECTIVES AND DEFINITION OF PPC........................................................... 26
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
• structure organization • work process organization
3.1.1 Structure organization Arrangement and organizational structuring of enterprises/operations according to principles of division of labour and organizational units (work places, divisions) as well as their cooperation/communication and coordination processes
(Birker)
monolithic line organization specialization of functional areas
P P
staff line organization
Management
Sales R & D OperationsMarketing
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
3.1.2 Process organization Special and temporal arrangements of work functions along the supply and production chain within the operational structure. The process organization regulates the activities for execution of tasks
(Birkel) 3.2 Systematic of Industrial Engineering six levels of analysis: 1st level: Enterprise/Company Macro level 2nd level: plant 3rd level: manufacturing area / planning area Meso level 4th level: work team 5th level: work place 6th level: job/function Micro level
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
standard time Time required by a average skilled operation, working at normal pace to perform a special task using a prescribed method allowing time for personal needs, fatigue(Ermüdung) and delay.
29.10.2003 6 Case study 2 Transfer of production of printed circuit boards to Signa /Cz Situation:
- Martin GmbH, Berlin wants to outsource the production and test of printed circuit boards (PCB) for the product program of Martin GmbH to Signa.
- Martin has a program of 40 different PCB`s with yearly volume from 50 units/ year to 10 000 units/year.
- The make or buy-analysis was done and the management decision was to outsource the production of PCB`s to Signa.
Signa:
- Specialized company for the production of PCB`s and test of PCB`s ATEX approved and certified ISO 9001:2000
- State of the art insertion and test machines (SMD devices etc) - 3 shifts operation - Spray coating equipment for PCB`s - 50 employees, engineering department for PCB layouts - CAD –system in use - Test adapters and test programs made by Signa
Tasks:
- The operations manager of the Martin GmbH has installed a team to manage the transfer.
- Team members are engineers of R&D, Industrial Engineering, Production, Cost Accounting, Production Control and Purchase Department
1. Create a team chart for this team 2. Which product documentations are needed for the transfer? 3. Define the potential steps for the transfer 4. Define a milestone plan for the transfer 5. Transfer of special equipment and fixtures to Signa
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
Transfer of production of printed circuit boards to SIGNA
Mission Statement
Transfer of production technology and necessary information of PCB-production to Signa, Czech Rep. enabling them to produce at same standards and output volume. Ensuring the right amount of PCB’s in the right time, right location and right quality.
Team Inputs
Information of present production 1. Risk Management: Plan “B” 2. Analysis of PCB portfolio (40 types, ABC-distribution) 3. Information politics 4. Basic data (documentation) 5. capacity planning for the next 6 months 6. Check of SW-compatibility 7. Copy of Test-SW 8. Direct contact with sufficient language skills (interpreter necessary?) 9. Interfaces of processes 10. Decision: Who is supplier for components of PCB’s? (Supply Chain
Management) 11. Logistics: Transportation, delay due to customs, etc. 12. Outgoing or incoming quality tests?
Team Goals & Outputs
Project goals • Project finish (production running 100% of present volume and quality)
end of April 2004 • Meet target costs
Output: • Documentation • Project plan • Validation of processes
Team Members
Team leader Team sponsor
• John Beschnidt • Andreas Reichert • Philipp Hartmann • Heiko Boelter • Haifeng Li • Russell Sahusilawane • Phillip Kern • Florian Hieber
Group Responsibilities
Successful transfer within cost and time limit Guarantee the communication between teams Guarantee the sufficient supply of PCB’s during transfer time and afterwards
Timing
1. Visit Signa plant 2. Documentation of processes (BOM, Routing Plan, test plans, etc.) 3. Define contacts 4. Feasibility study for emergency plan 5. Parallel production during transfer 6. Extended stock production (300%) 7. Pilot run
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
6.2 Which product documentations are needed for the transfer? Product documentation necessary for transfer Product information Process information
• Drawings • BOM • Routing Plans without minutes • Test plans • Test adapters • Special condition instruction
(e.g. coating) • Samples
• Agreed project schedule • Agreed production schedule
(transfer and rolling forecast) • Supplier specifications (incl. names
and prices) • Electric circuit plans • Quality history • R&D experience
6.3 Define the potential steps for the transfer
Define the potential steps for the transfer (incl. milestones) 1. Analysis of portfolio (2 weeks) ABC-Matrix 2. Collect documentation and translation (6 – 8 weeks) Phase 1: Drawing,
BOM, Routing, test sheets 3. Agree on schedules 4. Transfer of A-Runner PCB
6.4 Define a milestone plan for the transfer s.a. (6.3) 6.5 Transfer of special equipment and fixtures to Signa Transfer of special equipment and fixtures to Signa
1. know-how-transfer 2. disassembly of equipment 3. transportation 4. setup of equipment 5. test of equipment 6. know-how-transfer
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
- sales statistics - market development - orders you already have
normally done by sales department 2004 2005 Jan Feb March April … Jan Feb product A 1000 1000 800 product B 500 500 400 … product C 900 800 700 product D 800 900 you need this information to order from the supplier especially with respect to long delivery times
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern
10 Order processing and Production Planning & Control (PPC) 10.1 Tasks, Objectives and Definition of PPC 10.1.1 Order Processing, Production Planning & Control (PPC) and Enterprise
Resource Planning
10.1.2 Production, Planning & Control (PPC) – Tasks and Objektives
10.1.3
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International Technology Transfer Management
Industrial Engineering Dr. rer. nat. Dieter Lubkoll
Wintersemester 2003/2004 Lecture Notes by Phillip Kern