DEPARTMENT : MATERIALS

INCHARGE : MR.J.CHRISTOPHER

INDEX : PROCESS INNOVATION OF MATERIALS

 MATERIALS ORGANISATION
MATERIAL
MATERIALMANAGER
MANAGER
(VACANT)
(VACANT)

R.HARIKRISHNAN
Vacant J.CHRISTOPHER
J.Christopher
(Asst.Manager)
(Engineer) (Asst.Manager)
(Sr.Executive)

K.SIVAKUMAR
K.Sivakumar I.A.C .Maravarman
(Asst.Executive) (Asst.Executive)

PHI WORKERS J.Birunthai

(8) (Jr.Executive - CL)

CL WORKERS
(7)
 BEFORE INNOVATION AFTER INNOVATION
 We made cost saving plan 2010 & We are making cost saving plan 2010
2011. No Updation for many new   & 2011. Updation for every new items.
items.

Stores Closing Stock Value More Than Stores Closing Stock Value Less Than
 
Target Value (6.5 cr) Target Value (6.5 cr)


Monthly purchase comparison Now every month purchase
 
Not made comparison making


KD Receipts Inward Value Based on KD Receipts Inward Value Based on
monthly exchange rate   Receiving Date exchange rate
 BEFORE INNOVATION AFTER INNOVATION

Non Moving Materials & KD All materials Sent Back To Korea With
Rejections Kept In Stores Long Time Sales Value


Air Freight Charges Paid By PHI Due To Air Freight Charges Reduced, Safety
Material Shortage Level Stock Maintained In Stores


   MATERIALS ORDER PROCESS

PURCHASE ORDER PROCEDURE - CURRENT POSITION - KD

SL.NO CLASSIFICATION SOURCE STOCK DAYS IN TRANSIT ORDER QTY DAILY USE APPROVAL

 
1 CHILD PARTS & CHEMICALS PAVCO 55 DAYS 21 DAYS 55 DAYS STOCK + INTRANSIT 3 MONTHS AVG / DAY DGM/ED

2 RUBBER (CMB) TPHE 45 DAYS 21 DAYS 45 DAYS STOCK + INTRANSIT 3 MONTHS AVG / DAY DGM/ED

3 CMB CHEMICALS PHCMB 45 DAYS 21 DAYS 45 DAYS STOCK + INTRANSIT 3 MONTHS AVG / DAY DGM/ED

PURCHASE ORDER PROCEDURE - ( FROM ARP '10) - KD

SL.NO CLASSIFICATION SOURCE STOCK DAYS IN TRANSIT ORDER QTY DAILY USE APPROVAL
 
1 CHILD PARTS & CHEMICALS PAVCO 50 DAYS 21 DAYS 50 DAYS STOCK -INTRANSIT 3 MONTHS AVG / DAY DGM/ED

2 RUBBER (CMB) TPHE 50 DAYS 21 DAYS 50 DAYS STOCK -INTRANSIT 3 MONTHS AVG / DAY DGM/ED

3 CMB CHEMICALS PHCMB 50 DAYS 21 DAYS 50 DAYS STOCK -INTRANSIT 3 MONTHS AVG / DAY DGM/ED

PURCHASE ORDER PROCEDURE - LOCAL PARTS

SL.NO CLASSIFICATION SOURCE STOCK DAYS IN TRANSIT ORDER QTY DAILY USE APPROVAL

1 CHILD PARTS LP 3~4 DAYS DAILY BASIS 30 DAYS STOCK MONTHS AVG / DAY DGM/ED

2 RAW MATERIALS LP 45~60 DAYS WEEK BASIS 30~45 DAYS STOCK MONTHS AVG / DAY DGM/ED

3 CHEMICALS LP 15 DAYS WEEK BASIS 30 DAYS STOCK MONTHS AVG / DAY DGM/ED
 MATERIALS ORGANISATION
MATERIALS FLOW CHAT

MATERAILS RECEIVED

QTY CHECK / GRN PREPARED

OFFER TO QUALITY

OK - MATERIALS NOT OK - MATERIALS

MOVE TO STORES STOCK SEND BACK TO SUPPLIER WITH REJECTION INVOICE

MATERAILS ISSUE TO PRODUCTION AS PER REQUEST

STOCK UPDATE
 JOB RESPONSIBILITIES

SL.NO WORK DETAILS DAILY WEEKLY MONTHLY YEARLY RESPONSE

1 IMPORT DETAILS 0 CHRISTOPHER

2 IN TRANSIT DETAILS 0 CHRISTOPHER

3 PO RELEASED - PAVCO/TPHE 0 CHRISTOPHER

4 PENDING STATUS 0 CHRISTOPHER

5 PO AMENDMENTS - KD 0 CHRISTOPHER

6 TENTATIVE SCHEDULE 3 MONTH - TPHE 0 CHRISTOPHER

7 CUSTOMS DUTY 0 MARA

8 LOM FOLLOW UP 0 CHRISTOPHER/MARA

9 LOM PAYMENT 0 CHRISTOPHER/MARA

10 INVENTORY TREND 0 CHRISTOPHER

11 MONTHLY STOCK CLOSING 0 MARA

12 MONTHLY STOCK VALUATION 0 MARA

13 DAILY USE CALCULATE - 3 MONTHS AVG 0 CHRISTOPHER/MARA

14 PURCHASE ORDER VS RECEIPTS 0 0 CHRISTOPHER

15 MONTHLY PLAN MATERIALS - PPC 0 CHRISTOPHER/SIVA

16 A RAYMOND FOLLOW UP 0 CHRISTOPHER

17 KD MATERIALS BASIC PRICE 0 CHRISTOPHER

18 QUALITY ISSUE - KD 0 CHRISTOPHER/ARIVALAGAN

19 REJECTION CLAIM WITH QUALITY 0 CHRISTOPHER/ARIVALAGAN

20 TS 16949 - DOCUMENTAION 0 0 CHRISTOPHER/MARA

21 5 STAR - UPDATE 0 0 CHRISTOPHER/SIVA

22 NEW DEVELOPMENT MATERIALS 0 0 CHRISTOPHER/PANDIAN

23 PREMIUM FREIGHT ( AIR FREIGHT DETAILS) 0 CHRISTOPHER

24 COST SAVING WITH DEVELOPMENT 0 CHRISTOPHER /DEVELOP

25 PO RELEASED - LP SUPPLIERS 0 NEW

26 WEEKLY SCHEDULE FOLLOW UP - LP 0 NEW

27 DELIVERY RATINGS 0 NEW

28 RM PURCHASE LOCAL 0 0 NEW

29 SHORTAGE / EXCESS CONTROL - LP 0 NEW

30 PO AMENDMENTS - LP 0 NEW

31 LP MATERIALS BASIC PRICE 0 NEW

32 LOCAL PART RATE REVISION 0 NEW

33 PRICE RECONSILATION - LOCAL SUPPLIERS 0 NEW

34 SUPPLIER OVERALL RATINGS ( TS 16949) 0 NEW

35 QUALITY PROBLEMS - LP 0 0 SIVA

36 NON MOVING STOCK STATUS 0 SIVA

37 SUPPLIER EVALUATION AUDIT ( TS 16949) 0 CHRISTOPHER/NEW

38 NEW SUPPLIER EVALUATION AUDIT 0 CHRISTOPHER/NEW

39 BUSINESS PLAN ( MATERIAL) 0 CHRISTOPHER

40 COST REDUCTION WITH DEVELOP 0 NEW/PANDIAN

41 TOOL COST AMORTIZATION WITH DEVELOP 0 NEW/PANDIAN

42 RM PRICE RECONSILATION (EVERY 3 MONTHS) 0 NEW/PANDIAN

43 GRN ( GOODS RECEIPT NOTE) IN TALLY (KD) 0 MARA

44 GRN ( GOODS RECEIPT NOTE) IN TALLY (LP) 0 SIVA

45 INVENTORY DATA IN EXCEL 0 MARA

46 KD MATERIAL DAILY STOCK IN EXCEL 0 MARA/BIRUNTHAI

47 PAYMENT VOUCHER - LP PARTS 0 MARA/BIRUNTHAI

48 REJECTION CLAIM - LP PARTS 0 SIVA/NEW

49 REJECTION TO SUPPLIER LP 0 SIVA

50 PERPETUAL STOCK TAKEN IN STORES 0 SIVA

51 MONTHLY PHYSICAL STOCK IN STORES 0 SIVA

52 DISPLAY BOARD DAILY UPDATION IN STORES 0 SIVA

53 RM SALES TO SUPPLIER & FOLLOWUP 0 SIVA/BIRUNTHAI

54 PRODUCTION PLAN STATUS - MATERIAL 0 SIVA

55 RETURNABLE & NON RETURNABLE DC FOLLOW-UP 0 SIVA

56 RAW MATERIALS (IN HOUSE) RECONCILATION 0 SIVA/MARA

57 HMI / HYSCO RM RECONCILATION 0 SIVA/BIRUNTHAI

58 MONTHLY STATIONERY REQUIREMENTS 0 BIRUNTHAI/SIVA