MATERIAL FLOW

SHARON MOLINA SUYU

TABLE OF CONTENT

Inventory control Quantity of inventory Physical Inventory Mechanized material

Handling

INVENTORY CONTROL

-Effective inventory control is aimed at ensuring that an adequate but not excessive bank of materials is on hand at all times to meet operating requirement.

INVENTORY CONTROL

*Most companies inventories perform two function

1.They act as “safety stocks” of the materials

2.Permit a company to operate with disconnected processes in the manufacturing and distribution cycles

QUANTITY OF INVENTORY

1.Replenishment requisition

2. Withdrawal requisition

3. Perpetual-inventory records

QUANTITY OF INVENTORY

Purchased requisition-To initiate inventory

replenishment orders with outside vendors .

QUANTITY OF INVENTORY

Manufacturing requisition-are issued by the stores

or inventory control personnel to initiate manufacturing order with the plant

QUANTITY OF INVENTORY

Material requisition-Materials are withdrawn

from the store room only upon receipt of a formal material requisition.

QUANTITY OF INVENTORY

Purchased requisition

-To initiate inventory replenishment orders with outside vendors .

1. ORDER POLICY

A. Minima are set so that, when fresh stock arrives, a small reserve of material is still on the shelves

B. A stock cost occurs when an item is needed but not available

1. ORDER POLICY

C. Material in stock incurs certain carrying charges called cost of possession which makes it desirable to carry low average inventory.

D. Each time material is ordered ,certain cost of acquisition are incurred which make it more desirable to order large quantities infrequently than to order small quantities frequently

1. ORDER POLICY

A. Minima are set so that, when fresh stock arrives, a small reserve of material is still on the shelves

B. A stock cost occurs when an item is needed but not available

1. ORDER POLICY

C. Material in stock incurs certain carrying charges called cost of possession which makes it desirable to carry low average inventory.

D. Each time material is ordered ,certain cost of acquisition are incurred which make it more desirable to order large quantities infrequently than to order small quantities frequently

2. MATERIAL IDENTIFICATION

Standard industrial practice classifies ,through the use of symbols, all materials,parts,and products, as well as operation, department,

machine factory accounts ,occupation or jobs.

2. MATERIAL IDENTIFICATION

At this point we are concerned principally with the identification of materials by means of either numerical or mnemonic symbol.

PHYSICAL INVENTORY

Method Used in taking the physical inventory

1. Inventory at a stated time annually covering all items at that time.

2. Periodic physical inventories of all items during the course of the year so that each item is inventoried at least once a year.

PHYSICAL INVENTORY

Method Used in taking the physical inventory

3. Inventory of item whenever the stock on that item reaches its lowest point. Under this system, items are inventoried irregularly ,but the time for the actual inventory is reduced to a minimum because of the small quantities involved.

STOREROOM LOCATION AND LAYOUT

The material storerooms are located close to the point of use. Raw materials are logically stored near the first operation, finished goods in the proximity of the shipping area, banks of in-process materials immediately ahead of the next operation, and supplies and tools in a location central to the personnel and equipment served.

STORAGE FACILITIES

Major percepts upon which the selection and installation of a storage facilities are generally based may be stated as follows:

1. Allows for easy ,quick ,and sure receipt ,storage and disbursement of materials.

2. Provide spaced and storage equipment adequate as to both size and load-bearing capacity for the material to be stored.

3. Protect against damage and deterioration.

4. Provide means for identifying and readily locating contents.

5. Provide for the selection of the oldest material first.

STOREROOM OPERATION

A major premise of stockroom operation is the fixation of responsibility for the operation and control of that stockroom in the hands of one individual.

MECHANIZED MATERIAL HANDLING

ADVANTAGES OF MECHANIZED HANDLING PROPERLY INTEGRATED WITH PROCESSING MAY BE SUMMED UP AS FOLLOWS:

1. The manufacturing-cycle time can be reduced by the elimination of much non productive time in the manufacturing process. Authorities have calculated that at least 30 percent of the total time required in manufacturing is consumed by material handling.

2. Human fatigue in lifting and handling manually can be reduced and in some cases eleminated.Thus,much of the hard physical labor associated with many industrial processes is gone forever

3. Idle machine and employee can be brought to a minimum. Most of the waiting for work that occurs where intermittent and none mechanical delivery of materials is involved can be eliminated by equipment that ensures a steady constant flow of materials.

4. The productivity of employee working on the product is increased by a reduction of the time they would otherwise sprnd in handling materials

5. Increased safety of handlimg results where materials are not “ man – handled” mechanical equipment never suffers back injures,hernias, or toe accidents.

6. Storage space is conserved ,particularly where mechanical equipment is used to stack materials vertically

7. Nonproductive ,indirect labor can be released for more productive, direct labor activities

8. Certain types of mechanized handling tied in with automatic machine control open up vast possibilities in the field automation.

Types of material handling equipment

1. Hand trucks

- These include the four wheel hand lift truck used for transporting skids and platforms

2. Truck tractors

These are generally small but powerful gas -powered tractors used with trailers.

3. Power lift truck

A very useful type of equipment in any plant ,these truck are gas or electrically powered and are provided with either an elevating platforms, a set of tearing forks, a ram, or a crane, depending upon the application for which they are intended.

4. Stackers

Being only moderately mobile, the stacker is used primarily for the vertical stacking of heavy or bulky articles.

5.Gravity roll conveyors

Constituting perhaps the most widely used conveying means employed in industry today, this are used to convey materials on ball bearing rollers down a gentle grade by utilizing the natural force of gravity.

6. Power conveyor

Are frequently used in application where gravity-roll conveyor are not practicable, as would be the case where small individual part are conveyed separately or where vertical or sloping changes in elevation as from one floor to the next are required.