UNIVERSITI TEKNIKAL MALAYSIA MELAKA - eprints.utem.edu.myeprints.utem.edu.my/5297/1/Design_And_Develop_PCB_Half_Populated...Material Management team (MMT) department and production

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

DESIGN AND DEVELOP PCB HALF POPULATED SUBSYSTEM

OF MANAGEMENT INVENTORY SYSTEM AT MOTOROLA

This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering

(Manufacturing Management) with Honours.

by

NORAFIZA BINTI JAMA

FACULTY OF MANUFACTURING ENGINEERING

2011

DECLARATION

I hereby, declared this report entitled “PCB Half Populated Subsystem of Management

Inventory System” is the results of my own research except as cited in references.

Signature : ………………………………………….

Author’s Name : …………………………………………

Date : …………………………………………

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a

partial fulfillment of the requirements for the degree of Bachelor of Manufacturing

Engineering (Manufacturing Management) with Honours. The member of the

supervisory committee is as follow:

(Signature of Supervisor)

……………………………… (Official Stamp of Supervisor)

i

ABSTRACT

Inventory system in manufacturing industry is necessary and part of management

system. The case of this project will take at Motorola inventory system. Inventory

involved in this industry are parts, PCB board and PCB Half Populated board. This

study is about to develop a subsystem of inventory system that can be applied in

manufacturing industry. Main objective is to develop this system is to provide functions

for user to view PCB Half Populated item on-line, to record alls the item’s transactions,

update tracking the PCB Half Populated board and to reduce the cycle time of

production when requesting items for Motorola Penang Technoplex. The system uses

Visual Basic (VB) and Structured Query Language (SQL). The system benefit to

Material Management team (MMT) department and production line dealing with the

PCB Half Populated board store by making it faster, more accurate and easier.

ii

ABSTRAK

Sistem persediaan dalam industri perkilangan memerlukan sistem pengurusan yang

sistematik. Persediaan yang terlibat dalam industri perkilangan ialah komponen

elektronik, papan rangkaian tercetak dan separuh papan rangkaian tercetak yang telah

diletakkan komponen elektronik. Penyelidikan ini adalah untuk membangunkan sistem

persediaan yang boleh diaplikasikan dalam industri perkilangan. Tujuan utama untuk

membangunkan sistem ini adalah untuk menyediakan fungsi bagi pengguna untuk

mengendalikan separuh papan rangkaian tercetak berhubung secara on-line, mencatat

sagala data item, mengemaskini data dan mengurangkan pengambilan masa untuk

mengemaskini dan mencatat data secara online berbanding secara manual sebelum ini.

Sistem ini menggunakan Visual Basic (VB) dan Structured Query Language (SQL).

Kebaikan sistem ini ialah penggunaan bahagian pengurusan bahan dan bahagian

pengeluaran produk dalam berurusan mengenai permintaan atau penyerahan separuh

papan rangkaian tercetak yang telah diletakkan komponen elektronik dengan

menghasilkan pengurusan yang lebih cepat, lebih tepat dan lebih mudah.

iii

DEDICATION

Dedicated to my beloved parents Haji Jama Bin Mat and Hajjah Che Puteh Binti Ariffin

for being there always to give moral support and encouragement.

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ACKNOWLEDGEMENT

Many people and forces made this project achievable. First and Foremost “Syukur

Alhamdulillah”, praise to Allah SWT for his permission, strength, and patient given to

us that made possible the completion on this project.

In implementing the project, I would like to express my heartiest gratitude to my

supervisor, PM Dr. Adi Saptari, for the invaluable ideas, advices, guidance, critics, and

encouragement. Highest appreciation conveys to Dr Abdul Samad Hasan Basari dean

FTMK, who had spends he valuable time advice me on how to design and construct the

system. Not forgetting my classmate of BMFU and FKP lecturers for giving me the

hope, motivation and confidence to successfully complete this master program.

Last but not least, thanks to my family for all the unconditional love, endless support

and tolerance that will be remembered forever.

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TABLE OF CONTENT

Abstract i

Abstrak ii

Dedication iii

Acknowledgement iv

Table of Content v

List of Tables vi

List of Figures vii

List Abbreviations viii

CHAPTER 1 INTRODUCTION

1.1 Background 1

1.2 Motorola Information and Management System 1

1.2.1 Current System in Motorola 2

1.3 Statement of the Problem 2

1.4 Objectives 3

1.5 Scope 3

1.6 Chapter Summary 4

CHAPTER 2 LITERATUREREVIEW

2.1 Introduction of Management Inventory System 8

2.2 Key Element in Developing the System 9

2.3 Data Model 10

2.3.1 Database Management System (DBMS) 10

2.3.2 Data Warehouse 11

2.4 Internet Technologies 13

2.4.1 Web Technologies 13

2.4.2 Internet Security 15

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2.5 Model of a Web Database Application 17

2.6 Web Servers 20

2.7 Current Development of Management Information System 21

CHAPTER 3 METHODOLOGY

3.1 Introduction 26

3.2 System Development Approach 27

3.3 Spiral Model 27

3.4 Chapter Summary 32

CHAPTER 4 ANALYSIS AND DESIGN

4.1 Introduction 33

4.2 Requirements 35

4.2.1 Functional Requirement 36

4.2.1.1 Managing Requirement 36

4.2.1.2 Managing Inventory 37

4.2.2 Requirement software & Hardware 38

4.3 Analysis 39

4.4 Design 40

4.4.1 The System Activity 43

4.4.2 Design Interface and Functions 43

4.5 Implementation 47

4.6 Conclusion 48

CHAPTER 5 RESULT AND DISCUSSION

5.1 Introduction 50

5.2 Customer Responds 50

5.3 Impact of System to User 51

5.4 Impact of Implementing System to Reduce Scarps 52

5.5 Impact in Reducing Cost 54

5.6 Discussion 57

vii

5.6.1 Integration of Subsystem in PCB Half Populated Subsystem of Management

Inventory System 57

5.6.2 Maintenance System 58

5.7 Advantages of Implementation 59

CHAPTER 6 CONCLUSIONS & RECOMMENDATION

6.1 Conclusion 61

6.2 Recommendation 61

REFERENCES 63

APPENDICE S

APPENDICE A

APPENDICE B

APPENDICE C

APPENDICE D

APPENDICE E

APPENDICE F

viii

LIST OF TABLES

2.1 Summary Pervious Journal 22

4.1 A Summary of Users and Their Current Responsibilities 35

4.2 View request 36

4.3 Request Form Content 37

4.4 View Inventory 37

4.5 Update Inventory 38

4.6 Software in develop inventory system 38

4.7 Hardware in develop inventory system 39

4.8 Problem Statement and Problem Resolve 40

4.9 Data Definition Language of SQL 44 4.10 Data Manipulate Language (DML) 44 5.1 Model of Motorola product 56

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LIST OF FIGURES

2.1 A browser communicates with the web server 14

2.2 A firewall is being placed between the internet an organization’s 17

Networks

2.3 The three-tier architecture model of a web database application 18

2.4 The Implement Inventory System Database Work Flow 21

3.1 A simple spiral model 28

3.2 Logic Flow Chart of PCB Half Populated Management Inventory System 32

4.1 The flow chart of develop the subsystem prototype and test run 34

4.2 PCB Half Populated Subsystem of Management Inventory System 41

Architecture

4.3 Propose System Concept 42

4.4 PCB Half Populated Subsystem of Management Inventory System 42

Interface Chart

4.5 PCB Issue Half Populated View 45

4.6 Production Return Half Populated to MMT 45

4.7 View/Edit PCB Half Populated Issue 46

4.8 PCB Issue Form 47

5.1 Impact from questionnaire feedback. 51

5.2 Impact of System to User 52

5.3 Impact before subsystem Develop 53

5.4 Impact after Subsystem Develop 54

5.5 Cost scrap before subsystem development 55

5.6 Cost scrap after system development 56

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LIST OF ABBREVIATIONS

CSS - Cascading Style Sheets

DBMS - Database Management System

HTTP - hyper-text transfer protocol

IT - Information Technology

IS - Information System

IP - Internet Protocol

IE - Internet Explorer

MMT - Material Management Team

MIS - Management Inventory System

PCB-HPB - PCB Half Populated board

PCB - Printed Circuit Board

R&D - Research & Development

RDBMS - Relational DBMS

SQL - Structured Query Language

VB - Visual basic

WIP - Work In Process

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CHAPTER 1

INTRODUCTION

1.1 Background

Motorola Penang is the forerunner in the industrial and business on portable radio

communication equipment. This equipment like radio pager, handle walkie-talkies and

vehicles mobile radio are high products intended for industrial users, police safety

authorities, small business farmer and etc. in the United States and worldwide.

Motorola Penang, which began as a feeder factory today, serves a worldwide customer

base. Operations that started out as low technology and low skill have evolved into very

sophisticated, state of art and computer driven operations involving complete assembly,

testing failure analysis and research and development activities.

Motorola Penang is located on an 8-acre site in the Bayan Lepas Free Trade Zone, it has

a work force of about 3000 engaged in Research & Development (R&D), Product

Engineering, Advanced Assembly and Test Processes with a high degree of automation.

1.2 Motorola Information and Management System.

As a giant organization that has branches worldwide, Motorola used up-to-date

technology to make sure they perform well in producing the highest quality products.

Along with their vision to make paperless environment in all processes involved inside

the factory, Motorola used intranet (and also extranet) that connect them to other

2

Motorola worldwide besides using it to share knowledge and information. It can be said

that every tasks handled in Motorola Penang are computerized from processes involved

in manufacturing line until daily briefing session that were used to announced any

notice for Motorola. All were published through the intranet.

1.2.1 Current System in Motorola.

PCB (Printed Circuit Board) and PCB Management System is just like a one platform

inventory check list, activity of PCB board and parts running will preview at PCB

Management System. PCB Management System is an Information System created by

Motorola around March, 2002. PCB Management System keeps all type of PCB board

and part lists and their quantity into the management tracking system. All activities of

request and receive parts or PCB board from production and supplier were kept into

PCB Management System.

1.3 Statement of the Problem

The current management systems only update, list and view the fresh quantity of PCB

board and parts. PCB Half Populated board which is a work in process (WIP) of PCB

board, PCB Half Populated board did not keep in management tracking system. All

activities of request and receive will be updated using Microsoft excel by Material

Management Team staff. This program is a separate program not connected to the

management system. Work in process (WIP) of PCB board half way parts already

mount into PCB board surface and uncompleted to final inspection cause of no parts,

machine problem or waiting part from supplier. Production cannot keep the PCB Half

Populated board at line and have to return to Material Management Team (MMT)

department. The PCB Half Populated will request by production when the same model

run again.

3

PCB Half Populated board has a life expectancy and cannot keep for a longer time. If

PCB Half populated keep longer than life of expectancy, it has to be scraped. Cost of

one PCB Half Populated is depending how many parts mount at PCB board surface.

Since the PCB Half Populated board (PCB-HPB) updated in department computer, and

used Microsoft excel to keep track the quantity, it could not preview to all other staffs

especially production staff.

1.4 Objectives

The objectives of developing this PCB Half Populated Subsystem of Management

Inventory System are:

a) To develop a web based management inventory system that will be able to manage

and monitor inventory of PCB Half Populated.

b) To reduce cost due to scrap.

1.5 Scope

This project scope only in Material Management Team (MMT) department at Motorola.

The area of work concentrated on managing PCB Half Populated Inventory. However

this prototype may be implemented in any other department. The management

inventory system develop should have functions; to view request item on-line, to record

all items transactions happened, to reduce the time for requesting items and to reduced

quantity scrap of PCB Half Populated.

4

1.6 Chapter Summary

From the initial study, it is found that Motorola Technoplex Penang requires a PCB

Half Populated Subsystem of Management Inventory System that can reduce cost due to

scrap. The purpose of the project is to develop a new management inventory system

form isolated locations into a centralized database. A client server type of environment

and a web-enabled kind of application is required, as this will easily enable remote

access to the system by the users at anytime. This new system will enable sharing of

information by different category of Management Inventory System within Motorola

Technoplex Penang, eliminate inconsistency of information between the departments or

divisions, and also improve communication with the external parties such as Material

Management Team and Production Leader by extending the usage to them. It is hoped

with this new develop system put in into PCB Management System enable to resolve

the above mentioned problems, and further on, enable the users have the flexibility to

directly access the information as and when is necessary.

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CHAPTER 2

LITERATURE REVIEW

2.1 Introduction of Management Inventory System.

Inventory management is primarily about specifying the size and placement of stocked

goods. Inventory management is required at different locations within a facility or

within multiple locations of a supply network to protect the regular and planned course

of production against the random disturbance of running out of materials or goods. The

scope of inventory management also concerns the fine lines between replenishment lead

time, carrying costs of inventory, asset management, inventory forecasting, inventory

valuation, inventory visibility, future inventory price forecasting, physical inventory,

available physical space for inventory, quality management, replenishment, returns and

defective good and demand forecasting. Other definitions of inventory management

from across the web:

a) Involves a retailer seeking to acquire and maintain a proper merchandise assortment

while ordering, shipping, handling, and related costs are kept in check.

b) Systems and processes that identify inventory requirements, set targets, provide

replenishment techniques and report actual and projected inventory status.

c) Handles all functions related to the tracking and management of material. This

would include the monitoring of material moved into and out of stockroom locations

and the reconciling of the inventory balances. Also may include ABC analysis, lot

tracking and cycle counting support.

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d) Management of the inventories, with the primary objective of determining

controlling stock levels within the physical distribution function to balance the need

for product availability against the need for minimizing stock holding and handling

costs.

e) In business management, inventory consists of a list of goods and materials held

available in stock.

f) An inventory can also be a self examination, a moral inventory.

2.2 Key Element in Developing the System

To develop a Management Inventory System (MIS) based on computer system, it needs

key element. There are four key elements required which are as follows:

a) People

i. A team to develop and implement the system.

ii. The users. Two types of users consist of those who are going to input the

information into the system, and those who are using the system to view

information or executing relevant reports for supporting or decision making

purposes. Both types of users are very important to provide the user

requirements, which will enable to further define the functional requirements

and processes required of the new system.

b) Information Technology (IT)

Hardware, software and telecommunication networks (Robert, 2005). Basically, it is

the infrastructure to provide communication links between users and servers,

including gateway to internet for external parties’ communication. IT facilitates the

acquisition, processing, storing, delivery and sharing of information and other

digital content (Robert, 2005).

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c) Information System (IS)

Basically, IS is a mean by which people and organizations, utilizing technology,

gather, process, store, use, and disseminate information (Robert, 2005).

2.3 Data Model

It is significant to be exposed with available data model types that will later help to

determine the one that suits develop system inventory. There are many ways to store the

information. Each data model type has its unique architecture, capability and purposes.

In this research study, some selected data model types will be discussed for the purpose

of this development PCB Half Populated Subsystem of Management Inventory System.

2.3.1 Database Management System (DBMS)

A database is an organized collection of related data with the objective that the data can

be easily found whenever it is required. A database management system or DBMS

performs numerous functions in organizations, including the storage and retrieval of

data and metadata, the limit and control of redundancy, the support of simultaneous data

sharing, the provision for recovery and security services, the enforcement of business

rules and data integrity, and the improvement of programming productivity (K. Keeton,

December 1998).

Basically, DBMSs can differ widely based on the way a DBMS organizes information

internally. There are four types of data models reflect the logical relationships among

data in a DBMS. They are as relational, network, flat, and hierarchical. Different DBMS

supports different query language. The internal organization can affect how quickly and

flexibly you can extract information.

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A commonly used database type is RDBMS (Relational DBMS) model. It is a type of

data object (called an entity), which is a person, event, or thing about the collected data,

is described by a table (called a relation) of rows (called tuples) and columns (called

attributes). This relational model provides for logical connections among entities by

including certain unique data in its tables (K. Keeton, December 1998).

2.3.2 Data Warehouse

A database built to support information access. Typically a data warehouse is fed from

one or more transaction databases. The data needs to be cleaned and restructured to

support queries, summaries, and analyses.

According to Vivek R. Gupta, Senior Consultant in a white paper derived from Data

Warehousing with MS SQL, a data warehouse is a structured extensible environment

designed for the analysis of non-volatile data, logically and physically transformed from

multiple source applications to align with business structure, updated and maintained

for a long time period, expressed in simple business terms, and summarized for quick

analysis. Usually the data stored for business analysis is most effectively is separated

from the data in the operational systems (J. L. Hennessy, 1999).

Data warehousing systems are most successful when data can be combined from more

than one operational system. Traditionally, before the evolution of structured data

warehouses, analysts in many instances would combine data extracted from more than

one operational system into a single spreadsheet or a database. The data warehouse may

very effectively combine data from multiple sources applications such as sales,

marketing, finance, and production and also allow the source applications of to be

integrated into the data warehouse incrementally. The primary reason of this

combination is the ability to cross-reference data from these applications. Nearly all

data in a typical data warehouse is built around the time dimension because it is the

primary filtering criterion for a very large percentage of all activity against the data

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warehouse such as queries for a given week, month, quarter, or a year activity. The time

dimension in the data warehouse also serves as a fundamental cross-referencing

attribute. For example, an analyst may attempt to access the impact of a new marketing

campaign run during selected months by reviewing the sales during the same periods.

The ability to establish and understand the correlation between activities of different

organizational groups within a company is often cited as the single biggest advanced

feature of the data warehousing system (J. L. Hennessy, 1999).

The data warehouse system can serve not only as an effective platform to merge data

from multiple current applications; it can also integrate multiple versions of the same

application. For example, an organization may have migrated to a new standard

business application that replaces an old mainframe-based, custom-developed legacy

application. The data warehouse system can serve as a very powerful and much needed

platform to combine the data from the old and the new applications. Designed properly,

the data warehouse can allow for year-on-year analysis even though the base

operational application has changed.

Today, data warehousing systems provide the analytical tools afforded by their

precursors. But their design is no longer derived from the specific requirements of

analysts or executives and data warehousing systems are most successful when their

design aligns with the overall business structure rather than specific requirements (J. L.

Hennessy, 1999).

2.4 Internet Technologies

Today, Internet has become the most important tool for people to communicate, either

through emails or online chats, and to do research, upload or download software, e-

business, publishing and so on, via a web browser. With internet, communicate 24

hours, wherever and whenever they like.

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According to Daniel Amor, the internet means a network infrastructure that is built on

certain standards, the internet standards, which are used by all participants to connect to

each other. The specification of the internet protocol (IP) does not specify which type of

information, services or products should be exchanged but it defines how the flow of

information is organized. These specifications reside on a layer above the internet layer

and one of these protocols for the exchange of information is the World Wide Web with

its hyper-text transfer protocol (HTTP). There are other protocols too that enable people

to communicate via email, chat online (IRC) or newsgroups (NNTP). The web offers

the exchange of documents via HTTP which are mainly in HTML format, allowing

browsers to display the content in the correct way (S. S. Parekh, June 1998).

2.4.1 Web Technologies

In order to have an efficient internet communication that has fast response and reliable,

few elements of web technologies need to be explored in finalizing which technology to

be adopted.

a) Portal and Web Site

A portal is a “World Wide Web site that is or proposes to be a major starting site for

users when they connect to the Web or that users tend to visit as an anchor site” (E.D.

Bugnion, 2000). Portals contain lots of content in the form of news, information, links

and many other services. A web site is also a gateway of a company on the internet for

people to view and get information about the company via a URL (uniform resource

locator) that links the user with the web page.

b) Browser

Browser is a tool used to surf the internet. It forms a connection to a web server,

requests a web page, receives it, and brings it onto the computer screen as shown in