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1、DCC Performance and PracticeBy Snowden ChengBy Snowden ChengContents 1.Foxconns Strategy2.DCC Functionality in SAP system3.PO Management4.WW Sites Inventory Control 5.3S Balance6.EOL Control and EOL Liability Claim7.Sales Analysis and Invoice A/R Status Audition8.New Models Phase-in9.Tiptop Operatio
2、n and Paper workFOXCONNS STRATEGYOne Site DevelopingThree Sites ManufacturingWorld Wide DeliveringQuotationInquiryOrderDeliveryGoods issueBilling documentUpdate demandManagementRun MPS/MRPInventory ManagementUpdate FinancialsSDPPMMFI/CODCC Functionality In SAP SystemPO ManagementCALASSIFICATION OF P
3、OPO REVIEWDemands Analysis830 AND BLANK PO830 AND 24WKS SHIPPING PLANHOW TO DEAL WITH 850 830 COMMITMENT 870850 COMMITMENT 855CLASSIFICATION OF POBy time / period that PO covers1.Schedule PO /Discrete PO2.Blank POBy ways PO come in1.EDI2.E-mail3.FaxBy EDI (Main kinds)1.8302.850By Function of PO1.Eng
4、ineering Sample PO2.Cost PO ( including freight, tooling etc.)3.Normal POKEY POINTS OF PO REVIEWTo see whether it is from a new customer and old one.To see whether the required P/N is of our range.To check whether there is Export License.To see whether quantity is too small or too large.Conditions a
5、nd termsWhether we can meet required ETAWhether unit price is correctDelivery methods (by sea / air / Express)Destination of shipment.Whether Customer has specific forwarder.Whether there is any special requirement for packing.Demands Analysis830 AND BLANK POSame point: demands of them are very roug
6、h.Demands of 830 is changeable weekly.If blank PO is revised, PO No. will change.Normally, 830 is based on one blank PO.Blank PO cover possible total demands of one period of time (more than half a year)Normally, blank PO is one kind of 850, so structure of it is quite different from 830.If there is
7、 blank PO only and there is no 830 coming in, there will be no use of .830 & 24wks Shipping Plan24wks Shipping Plan is based on three important factors: 830, inventory and sales trend, and 830 is the most important one.In 24wks Shipping Plan, project buffer and inventory days are based on 830 direct
8、ly.From 830, we can analyze whole demand trend and curve of life circle, we can also analyze sales curve and compare it with 830 record in past weeks. That will be more helpful for us to arrange our 24wks Shipping Plan.HOW TO DEAL WITH 850Firstly, we have to review and to see whether:1.This 850 is E
9、ngineering PO / Cost PO 2.P/N in this PO is EOL model3.There have been some stocks now4.There are some raw materials now, if not, how long lead-time is .Commit 855 within 24hrs Inform contact window oversea and advise our best ETD and ETARelease PO to line to process Following up and traceAdvise pos
10、sible delay if some unexpected matter happen and necessary.830 COMMITMENT 870870 is our commitment to 830.870 commitment must be finished within 24hrs upon receipt of 830.870 commitment steps:1.830 example, please stick here now!2.870 commitment form, please stick here now!3.Key points: use inventor
11、y available now to commit demand of the 1st week, use ETA quantity of current week to commit demand of 2nd week, use ETA quantity of next week to commit demand of 3rd week, the rest can be deduced similarly.850 COMMITMENT 855850 example , please stick here now!855 commitment steps:1.step one, please
12、 stick here now!2.step two, please stick here now!WW Inventory ControlWhat drive the F.G inventory policy?What will effect the F.G inventory?How does Compaq handle the F.G inventory?How does Apple handle the F.G inventory?How does Dell handle the F.G inventory?What drive the F.G. inventory policy?Th
13、e worldwide supply vs. demand environmentThe agreement signed with the customerThe distance from manufacturing site to the sales marketThe product valueThe logistics modelWhat effect the F.G. inventory?The precision of the customers forecastThe competition among the competitorsThe manufacturing capa
14、city and flexibilityThe logistics capacity and flexibilityThe order/MPS process procedureThe supply chain management capabilityThe import/export handling capabilityHow does Compaq handle the F.G. inventory?The long term forecast direct the OEM partner market trendRequest for buffer stock to cover th
15、e market various nessPre-alert sent to OEM partner for approaching EOL Site transfer to balance world wide inventoryHow does Apple handle the F.G. inventory?The strict 13 weeks forecast drive the OEM productionThe special operation team watch the OEM plant activities very closelyTo control the whole
16、 F.G. pipeline movement from ex-factory to ex-hubPay the OEM partner F.G. inventory cost in timeDo not ask for F.G. buffer stockHow does Dell handle the F.G. inventory?The precise 18 weekly forecast stabilize the OEM partners productionThe multi-vendor supplies to cover the demand changeThe direct S
17、hip (CTO) and BTO business model reduce the uncertain effects distorting the manufacturing activity 3S BalanceWhat is 3S?Why “3S Balance” is very important?Year 2001 DT(1) General 3S Balance Accumulation What is “3S”?3S means:Shipping: Quantity shipped from LH to WW sitesSales: Quantity sent to Cust
18、omer from WW sites Stock: Quantity on pipeline: Inland + On-way +Container Yard + HUBWhy “3S Balance” is very important“3S Balance” means: normally, Balance = Open + Shipping Sales-Stock = 0. if not, that means something wrong with our operation, wherever.“3S Balance” is an very important index to r
19、eflect result of business and management“3S Balance” is a barometer: If stock is higher, we have to slow down our shipping and push our sales.Year 2001 DT(1) General 3S Balance AccumulationIf you want to see sample in Excel Sheet , Please stick If you want to see sample in Excel Sheet , Please stick
20、 HereHere now! now!EOL Control and EOL Liability ClaimEOL Pre-alert signal / Announcement EOL ControllingEOL Liability Report and ClaimEOL Pre-alert signal / AnnouncementWhen demands of forecast have been cut down sharply, and this trend last several weeks.When customer has asked us to review WW F.G
21、 inventory and raw materials.When customer has announced EOL When customer has asked us to hold all raw materialsEOL ControllingReview and check materials status weeklyAnalysis liability of EOL materials timely, and make judgment: whose liability and whyControl WW inventory under proper standard (da
22、ys) and pay more attention into sales trendNever work out new Liability or potential liabilityCheck and judge demands are true and false timely when demands are changeable fiercely.EOL Liability Report and ClaimBefore forward EOL Liability Report to customers, DCC will have to analysis and make sure
23、 that there are ample evidence to support report, the most important evidence is demands analysis (waterfall). If you want to see sample of waterfall,please stick hereEOL Liability Report will be worked out according to customer required form. Compaq required form is in hereEOL Liability Report will
24、 cover : WW pipeline F.G, semi-assembly, raw materials both in Foxconn and co-vendors, vendors raw materials both on hand and open orders.Forward EOL Liability Report to customers timely and push claimSales Analysis and Invoice A/R Status Audition2001 Compaq L5 Business Analysis ReportInvoice A/R Au
25、dition2001 Compaq L5 Business AnalysisFrom this report, DCC can tell you:1.Monthly sales and trend2.Full picture of annual sales3.Sales forecast of current and next weekIf you want to see sample of this report,please stick here now!Invoice A/R Audition To make sure WW sites to issue invoice for all
26、shipments sent to customer without any delay.To help Cost Dept to control WW sales and Invoice status.Daily Invoice Status, please stick here now!Some period Invoice Status, please stick here now!Variance between sales and invoice during period of time. Please stick here now!New Models Phase-inMain
27、Steps of DevelopmentRough Shipping Schedule for new Models MVB MVB and Force PartsP-BOMThree stages of Cycle Time for one ModelDCCs strategy to meet challenge of RampMain Steps of DevelopmentDevelopment Steps Explanation Tool DesignTool StartT1PV!PV2PV3TVR3BFAIFAIFAIMVBT1: it is this first time to r
28、un tooling PV1: 1st time to send sample to Customer for verification PV2: 2nd time to send sample to Customer for verification PV3: 3rd time to send sample to Customer for verification TVR: Tooling Verification Report FAI: First Article Inspection, it happens at any time between PV! and TVR3B: The s
29、tep of Customers final approval. MVB: Mass Volume Build, the very start point of rampRough Shipping Schedule for new Model1.If you want to see sample form “ Rough Shipping Schedule for new models” , please stick here now !2.What you can learn from “ Rough Forecast and Development Schedule?Where this
30、 new model will be sent to ?When PV2? When PV3 if necessary?When 3B?When MVB? How many pc for MVB? How to send them out? When Ramp begin?When some important materials are approved? Such as FDD, SPS , PCA and so on3.Before DCC receive normal 830 signal , DCC will put this rough forecast into shipping
31、 plan, all concerning Dept will prepare their MRP according it.4.Engineering Dept / DCC will forward this forecast to Custom Dept for applying for Export License.M V BWhat “ MVB” means? Mass Volume BuildWhen “ MVB” ? After new models sample has been approved ( 3B has passed)What “ MVB” is for? Pilot
32、 Run in Customers Production Line.After “MVB”, Ramp will begin.Quantity of “MVB” is usually very small.MVB and FORCE PARTS1.When we send shipment of MVB out to one site, we should send some FORCE Parts too ( at the same time)2.What does “ FORCE” stand for? Fall Out Replacement Component Exchange.3.F
33、orce is defined as components that are in the Level 5 enclosure that may fail at level 10 test.4.We position these components so the level 10 mfg does not need to tear down the level 10 to a level 5 enclosure them RMA it to us. All Force parts are free charge.5.Force parts are SPS / FDD/Cable / Spea
34、ker / Fan/Riser Card / solenoids (functions parts/assembly)5.How many pc for each FORCE parts?Quantity will base on value of parts.At some ratio ( 3% 5%) of MVB quantity.FAE OverseaCustomer ServiceCustomerDCC DeptP-BOMP-BOM parts are spare part that Compaq advise the level 10 mfg to position to be u
35、sed for repair of line fall out/ damage, these parts are purchased by the level 10 mfg for their use.P-BOM parts are painted access panels, painted chassis cover, bezels ( nonfunctional part/assembly)Three Stages of Cycle Time of one ModelThree Stages are : Ramp , Peak, EOLVolumeTimePeakEOLRamp4wks2
36、wks2wksDCCs Strategy to meet Challenge of Ramp 1.DCC will put Rough Forecast from Engineering Dept into Shipping Plan as soon as DCC get it even if tooling of some parts are unavailable.2.Pre- process enough buffer for some parts as soon as its FAI has been approved.3.When making shipping Plan, DCC
37、will put more than 3 wks buffer into Shipping Plan as soon as 3B is approved.4.Pay close attention to status of some bottleneck componentsM/B, CPU, Modem, DRAM, CD ROM/ CD RM, HDDFDD, SPS, Riser Card ( PCA Board)BufferDemandTiptop Operation and Paper workLoading ListInventory controlSales control an
38、d balance accountWW invoice auditionQuotation Application for Export LicenseDCCs Development PlanEnhance the teamContinuouslyby valuable trainingmotivate members being more creativeImprove the procedurebeing more efficientRaise a free circumstance, make the team being more productivedevelop personalcareer on the basicOf the team visionTurn out the widelyWin-to-win cooperationatmosphere
