In this article we continue to talk about the “Low volume High mix working system” from last article.

To let all of the information clear and rapid communication is an important management way now. PSI designs a production information management system to achieve real-time information collection and analysis by real time base. The system includes production response system and production history tracking system. All of the teams can see production status at the web page and recognize the delivery schedule, efficiency and quality status. When customer gives feedbacks on product problems, PSI can trace the production history to see the original cause and the range of the problem by product’s serial number. Then, we’ll solve the problem during earlier stage by the second system of MES - Production history tracking system.

Teams’ communication in low volume high mix production is complex. All of the procedures test the management capabilities of a company, such as production information flow, shortage control, kitting date handling, production schedule arrangement, SOP making, engineering change requirement and customization setting support. To make the information flow smooth and rapid, PSI designed the Kanban system. Teams in PSI can get all of the necessary information through working order number. Therefore, customer’s information can be delivered to the necessary teams by the earliest time.

It’s an important module in MES. PSI will collect all of the serial numbers for the key parts that the customer set. As soon as the customer reports a serial number after the products shipped , PSI can trace the production history and date code of the key parts and do the analysis immediately.

Product’s functions are more and more complex. All kinds of components on the board have increased currently. People sometimes make mistakes when loading the parts to SMT line and the review system get loss, too. To prevent the faults, PSI planned to build a wrong parts prevention system in Q3’2013. Then, the program coding and trial were finished in Q2’2014 and the system Operated in our production line in Q3’2014. We’ll reach the goal of zero fault in our SMT production.

It’s a tracking system for product repairing. After bad product are repaired, PSI will keep the record of defect status and repair status in the repairing system. Through analysis of the records, we can figure out the quality level of our production line. Also, we can trace the record as customer gives feedback on product problems.

There are 3 major modules for quality management system- Yield rate status, internal deviation management and customer complaints. After production, our system will count the yield rate status as the analysis base for Quality team. There are two purposes for the internal deviation management and customer complaints- one is analysis of deviation, improvement and trace. The other is to put the deviation into different products that are related the deviation automatically. As the product is built some days later, staff in production line can see the deviation history of the specified product and pay attention to the problem during production.

This system covers RMA in-out control, return for repairing and return for refund rate counting, RMA repairing record, RMA repairing analysis and improvement. We use RMA management system to know PSI’s shipped product quality level.

There are many communications and large size of data transfer between customer and PSI for low volume high mix production. To prevent misunderstanding during communication, PSI develops a system named real time information system. We hope PSI can communicate with customer without any gap.

*Backlog system

To deliver the backlog information on a daily basis, customers can check the backlog information after they provide PSI orders. Then, the two parties will always be consistent on the ordering information.

*Detail production schedule

When PSI receives the order, production control team member will use our own APS (Advanced Planning and Scheduling-System) to arrange the production schedule. Then, PSI will provide the production schedule in real time information system daily. Customers can see the detailed schedule and arrange their next steps.

*Material simulation report

Due to delivery time is more and more short, it becomes more important and more complex for material purchasing. PSI has a material simulation system running every night. The system can determine all of the incoming date for different working orders. Customers can see shortage of different orders with the remote access of system. Then, PSI can cooperate with customer to solve material shortage problem and let the production smooth.

*Customer unique parts list

PSI has a rule to set the material used by only one customer as unique parts (materials). If customer doesn’t use the unique parts for a certain period, customer needs to buy back the parts. The other advantage is customer can recognize the inventory of unique parts and plan the future order in advance.

*Customer consign parts list

Customers can see the consign parts list any time when they need to check.

*Finished quantities and yield rate report

PSI has a real time data collection system to collect production information. And the MIS system can generate some statistical reports. Customers can see the production quantities and yield rate at remote site.

*Kanban system

Customer can see PSI’s internal production information for specified product by purchasing order number or other way, no matter before production or during production. Customer can review the information and ensure PSI do the right thing.

*Daily Shipping report

PSI will create a shipping report on a daily basis when PSI ships goods to customer. Customer can trace the shipping products and quantities by the report.

*Serial number tracking system

If there’s any deviation from end customer, PSI’s customer can trace the production status of the product by serial number provided by the end customer. Also, customer can trace the production status and shipping status of the whole lot.

We have introduced the very important management system of PSI in two of the press release. Hopefully, PSI’s friends will know our progress better. PSI will improve the system continuously and try our best to provide customer advanced services.