Research On The Inventory Management Of Work In Process For FCY

FCY is an OEM factory founded in 2002, mainly manufacturing 2.5 inch and 1.8 inch Hard Disk Drivers assembled in notebook, finally the HDD are selled to the first class brand of notebook all over the world from FCY's customer, such as HP, SONY, TOSHIBA, APPLE etc. As the economic storm of 2008 gone away, the order demand from the beginning of 2009 has grown exponentially. In order to satisfy customer's demand to the greatest possible extent, and maximize our product market share, FCY setted up the unreasonable production plan which resulted in WIP out of control, especially, the NG QTY exceeded 60% of the output.In the thesis, FCY applied the 6 sigma method on the WIP management so as to find the key problem point and solve it in the following order: Define, Measuring, Analyze, Improve and Control. First, The problem and the target was defined. Second, FCY established a 6 sigma team to study the current situation of WIP. Third, in analysis step, the team member use brain storm and fish bone tools to list all potential reasons, and then use Pareto diagram to find out the most two important facts that the unreasonable production plan and that the WIP data couldn't match real product information. Base on the analyzed the reason, FCY experimented JIT production control method and TOC bind theory to improve the production plan method and minimized the information transfer module according to the production features of FCY to solve the unmatched information problem. Finally in the control step, the team will monitor the situation of WIP with control picture.