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UNIVERSITI TEKNIKAL MALAYSIA MELAKA
DESIGN AND DEVELOP PCB HALF POPULATED SUBSYSTEM
OF MANAGEMENT INVENTORY SYSTEM AT MOTOROLA
This report submitted in accordance with requirement of the Universiti Teknikal Malaysia Melaka (UTeM) for the Bachelor Degree of Manufacturing Engineering
(Manufacturing Management) with Honours.
by
NORAFIZA BINTI JAMA
FACULTY OF MANUFACTURING ENGINEERING
2011
DECLARATION
I hereby, declared this report entitled “PCB Half Populated Subsystem of Management
Inventory System” is the results of my own research except as cited in references.
Signature : ………………………………………….
Author’s Name : …………………………………………
Date : …………………………………………
APPROVAL
This report is submitted to the Faculty of Manufacturing Engineering of UTeM as a
partial fulfillment of the requirements for the degree of Bachelor of Manufacturing
Engineering (Manufacturing Management) with Honours. The member of the
supervisory committee is as follow:
(Signature of Supervisor)
……………………………… (Official Stamp of Supervisor)
i
ABSTRACT
Inventory system in manufacturing industry is necessary and part of management
system. The case of this project will take at Motorola inventory system. Inventory
involved in this industry are parts, PCB board and PCB Half Populated board. This
study is about to develop a subsystem of inventory system that can be applied in
manufacturing industry. Main objective is to develop this system is to provide functions
for user to view PCB Half Populated item on-line, to record alls the item’s transactions,
update tracking the PCB Half Populated board and to reduce the cycle time of
production when requesting items for Motorola Penang Technoplex. The system uses
Visual Basic (VB) and Structured Query Language (SQL). The system benefit to
Material Management team (MMT) department and production line dealing with the
PCB Half Populated board store by making it faster, more accurate and easier.
ii
ABSTRAK
Sistem persediaan dalam industri perkilangan memerlukan sistem pengurusan yang
sistematik. Persediaan yang terlibat dalam industri perkilangan ialah komponen
elektronik, papan rangkaian tercetak dan separuh papan rangkaian tercetak yang telah
diletakkan komponen elektronik. Penyelidikan ini adalah untuk membangunkan sistem
persediaan yang boleh diaplikasikan dalam industri perkilangan. Tujuan utama untuk
membangunkan sistem ini adalah untuk menyediakan fungsi bagi pengguna untuk
mengendalikan separuh papan rangkaian tercetak berhubung secara on-line, mencatat
sagala data item, mengemaskini data dan mengurangkan pengambilan masa untuk
mengemaskini dan mencatat data secara online berbanding secara manual sebelum ini.
Sistem ini menggunakan Visual Basic (VB) dan Structured Query Language (SQL).
Kebaikan sistem ini ialah penggunaan bahagian pengurusan bahan dan bahagian
pengeluaran produk dalam berurusan mengenai permintaan atau penyerahan separuh
papan rangkaian tercetak yang telah diletakkan komponen elektronik dengan
menghasilkan pengurusan yang lebih cepat, lebih tepat dan lebih mudah.
iii
DEDICATION
Dedicated to my beloved parents Haji Jama Bin Mat and Hajjah Che Puteh Binti Ariffin
for being there always to give moral support and encouragement.
iv
ACKNOWLEDGEMENT
Many people and forces made this project achievable. First and Foremost “Syukur
Alhamdulillah”, praise to Allah SWT for his permission, strength, and patient given to
us that made possible the completion on this project.
In implementing the project, I would like to express my heartiest gratitude to my
supervisor, PM Dr. Adi Saptari, for the invaluable ideas, advices, guidance, critics, and
encouragement. Highest appreciation conveys to Dr Abdul Samad Hasan Basari dean
FTMK, who had spends he valuable time advice me on how to design and construct the
system. Not forgetting my classmate of BMFU and FKP lecturers for giving me the
hope, motivation and confidence to successfully complete this master program.
Last but not least, thanks to my family for all the unconditional love, endless support
and tolerance that will be remembered forever.
v
TABLE OF CONTENT
Abstract i
Abstrak ii
Dedication iii
Acknowledgement iv
Table of Content v
List of Tables vi
List of Figures vii
List Abbreviations viii
CHAPTER 1 INTRODUCTION
1.1 Background 1
1.2 Motorola Information and Management System 1
1.2.1 Current System in Motorola 2
1.3 Statement of the Problem 2
1.4 Objectives 3
1.5 Scope 3
1.6 Chapter Summary 4
CHAPTER 2 LITERATUREREVIEW
2.1 Introduction of Management Inventory System 8
2.2 Key Element in Developing the System 9
2.3 Data Model 10
2.3.1 Database Management System (DBMS) 10
2.3.2 Data Warehouse 11
2.4 Internet Technologies 13
2.4.1 Web Technologies 13
2.4.2 Internet Security 15
vi
2.5 Model of a Web Database Application 17
2.6 Web Servers 20
2.7 Current Development of Management Information System 21
CHAPTER 3 METHODOLOGY
3.1 Introduction 26
3.2 System Development Approach 27
3.3 Spiral Model 27
3.4 Chapter Summary 32
CHAPTER 4 ANALYSIS AND DESIGN
4.1 Introduction 33
4.2 Requirements 35
4.2.1 Functional Requirement 36
4.2.1.1 Managing Requirement 36
4.2.1.2 Managing Inventory 37
4.2.2 Requirement software & Hardware 38
4.3 Analysis 39
4.4 Design 40
4.4.1 The System Activity 43
4.4.2 Design Interface and Functions 43
4.5 Implementation 47
4.6 Conclusion 48
CHAPTER 5 RESULT AND DISCUSSION
5.1 Introduction 50
5.2 Customer Responds 50
5.3 Impact of System to User 51
5.4 Impact of Implementing System to Reduce Scarps 52
5.5 Impact in Reducing Cost 54
5.6 Discussion 57
vii
5.6.1 Integration of Subsystem in PCB Half Populated Subsystem of Management
Inventory System 57
5.6.2 Maintenance System 58
5.7 Advantages of Implementation 59
CHAPTER 6 CONCLUSIONS & RECOMMENDATION
6.1 Conclusion 61
6.2 Recommendation 61
REFERENCES 63
APPENDICE S
APPENDICE A
APPENDICE B
APPENDICE C
APPENDICE D
APPENDICE E
APPENDICE F
viii
LIST OF TABLES
2.1 Summary Pervious Journal 22
4.1 A Summary of Users and Their Current Responsibilities 35
4.2 View request 36
4.3 Request Form Content 37
4.4 View Inventory 37
4.5 Update Inventory 38
4.6 Software in develop inventory system 38
4.7 Hardware in develop inventory system 39
4.8 Problem Statement and Problem Resolve 40
4.9 Data Definition Language of SQL 44 4.10 Data Manipulate Language (DML) 44 5.1 Model of Motorola product 56
ix
LIST OF FIGURES
2.1 A browser communicates with the web server 14
2.2 A firewall is being placed between the internet an organization’s 17
Networks
2.3 The three-tier architecture model of a web database application 18
2.4 The Implement Inventory System Database Work Flow 21
3.1 A simple spiral model 28
3.2 Logic Flow Chart of PCB Half Populated Management Inventory System 32
4.1 The flow chart of develop the subsystem prototype and test run 34
4.2 PCB Half Populated Subsystem of Management Inventory System 41
Architecture
4.3 Propose System Concept 42
4.4 PCB Half Populated Subsystem of Management Inventory System 42
Interface Chart
4.5 PCB Issue Half Populated View 45
4.6 Production Return Half Populated to MMT 45
4.7 View/Edit PCB Half Populated Issue 46
4.8 PCB Issue Form 47
5.1 Impact from questionnaire feedback. 51
5.2 Impact of System to User 52
5.3 Impact before subsystem Develop 53
5.4 Impact after Subsystem Develop 54
5.5 Cost scrap before subsystem development 55
5.6 Cost scrap after system development 56
x
LIST OF ABBREVIATIONS
CSS - Cascading Style Sheets
DBMS - Database Management System
HTTP - hyper-text transfer protocol
IT - Information Technology
IS - Information System
IP - Internet Protocol
IE - Internet Explorer
MMT - Material Management Team
MIS - Management Inventory System
PCB-HPB - PCB Half Populated board
PCB - Printed Circuit Board
R&D - Research & Development
RDBMS - Relational DBMS
SQL - Structured Query Language
VB - Visual basic
WIP - Work In Process
1
CHAPTER 1
INTRODUCTION
1.1 Background
Motorola Penang is the forerunner in the industrial and business on portable radio
communication equipment. This equipment like radio pager, handle walkie-talkies and
vehicles mobile radio are high products intended for industrial users, police safety
authorities, small business farmer and etc. in the United States and worldwide.
Motorola Penang, which began as a feeder factory today, serves a worldwide customer
base. Operations that started out as low technology and low skill have evolved into very
sophisticated, state of art and computer driven operations involving complete assembly,
testing failure analysis and research and development activities.
Motorola Penang is located on an 8-acre site in the Bayan Lepas Free Trade Zone, it has
a work force of about 3000 engaged in Research & Development (R&D), Product
Engineering, Advanced Assembly and Test Processes with a high degree of automation.
1.2 Motorola Information and Management System.
As a giant organization that has branches worldwide, Motorola used up-to-date
technology to make sure they perform well in producing the highest quality products.
Along with their vision to make paperless environment in all processes involved inside
the factory, Motorola used intranet (and also extranet) that connect them to other
2
Motorola worldwide besides using it to share knowledge and information. It can be said
that every tasks handled in Motorola Penang are computerized from processes involved
in manufacturing line until daily briefing session that were used to announced any
notice for Motorola. All were published through the intranet.
1.2.1 Current System in Motorola.
PCB (Printed Circuit Board) and PCB Management System is just like a one platform
inventory check list, activity of PCB board and parts running will preview at PCB
Management System. PCB Management System is an Information System created by
Motorola around March, 2002. PCB Management System keeps all type of PCB board
and part lists and their quantity into the management tracking system. All activities of
request and receive parts or PCB board from production and supplier were kept into
PCB Management System.
1.3 Statement of the Problem
The current management systems only update, list and view the fresh quantity of PCB
board and parts. PCB Half Populated board which is a work in process (WIP) of PCB
board, PCB Half Populated board did not keep in management tracking system. All
activities of request and receive will be updated using Microsoft excel by Material
Management Team staff. This program is a separate program not connected to the
management system. Work in process (WIP) of PCB board half way parts already
mount into PCB board surface and uncompleted to final inspection cause of no parts,
machine problem or waiting part from supplier. Production cannot keep the PCB Half
Populated board at line and have to return to Material Management Team (MMT)
department. The PCB Half Populated will request by production when the same model
run again.
3
PCB Half Populated board has a life expectancy and cannot keep for a longer time. If
PCB Half populated keep longer than life of expectancy, it has to be scraped. Cost of
one PCB Half Populated is depending how many parts mount at PCB board surface.
Since the PCB Half Populated board (PCB-HPB) updated in department computer, and
used Microsoft excel to keep track the quantity, it could not preview to all other staffs
especially production staff.
1.4 Objectives
The objectives of developing this PCB Half Populated Subsystem of Management
Inventory System are:
a) To develop a web based management inventory system that will be able to manage
and monitor inventory of PCB Half Populated.
b) To reduce cost due to scrap.
1.5 Scope
This project scope only in Material Management Team (MMT) department at Motorola.
The area of work concentrated on managing PCB Half Populated Inventory. However
this prototype may be implemented in any other department. The management
inventory system develop should have functions; to view request item on-line, to record
all items transactions happened, to reduce the time for requesting items and to reduced
quantity scrap of PCB Half Populated.
4
1.6 Chapter Summary
From the initial study, it is found that Motorola Technoplex Penang requires a PCB
Half Populated Subsystem of Management Inventory System that can reduce cost due to
scrap. The purpose of the project is to develop a new management inventory system
form isolated locations into a centralized database. A client server type of environment
and a web-enabled kind of application is required, as this will easily enable remote
access to the system by the users at anytime. This new system will enable sharing of
information by different category of Management Inventory System within Motorola
Technoplex Penang, eliminate inconsistency of information between the departments or
divisions, and also improve communication with the external parties such as Material
Management Team and Production Leader by extending the usage to them. It is hoped
with this new develop system put in into PCB Management System enable to resolve
the above mentioned problems, and further on, enable the users have the flexibility to
directly access the information as and when is necessary.
8
CHAPTER 2
LITERATURE REVIEW
2.1 Introduction of Management Inventory System.
Inventory management is primarily about specifying the size and placement of stocked
goods. Inventory management is required at different locations within a facility or
within multiple locations of a supply network to protect the regular and planned course
of production against the random disturbance of running out of materials or goods. The
scope of inventory management also concerns the fine lines between replenishment lead
time, carrying costs of inventory, asset management, inventory forecasting, inventory
valuation, inventory visibility, future inventory price forecasting, physical inventory,
available physical space for inventory, quality management, replenishment, returns and
defective good and demand forecasting. Other definitions of inventory management
from across the web:
a) Involves a retailer seeking to acquire and maintain a proper merchandise assortment
while ordering, shipping, handling, and related costs are kept in check.
b) Systems and processes that identify inventory requirements, set targets, provide
replenishment techniques and report actual and projected inventory status.
c) Handles all functions related to the tracking and management of material. This
would include the monitoring of material moved into and out of stockroom locations
and the reconciling of the inventory balances. Also may include ABC analysis, lot
tracking and cycle counting support.
9
d) Management of the inventories, with the primary objective of determining
controlling stock levels within the physical distribution function to balance the need
for product availability against the need for minimizing stock holding and handling
costs.
e) In business management, inventory consists of a list of goods and materials held
available in stock.
f) An inventory can also be a self examination, a moral inventory.
2.2 Key Element in Developing the System
To develop a Management Inventory System (MIS) based on computer system, it needs
key element. There are four key elements required which are as follows:
a) People
i. A team to develop and implement the system.
ii. The users. Two types of users consist of those who are going to input the
information into the system, and those who are using the system to view
information or executing relevant reports for supporting or decision making
purposes. Both types of users are very important to provide the user
requirements, which will enable to further define the functional requirements
and processes required of the new system.
b) Information Technology (IT)
Hardware, software and telecommunication networks (Robert, 2005). Basically, it is
the infrastructure to provide communication links between users and servers,
including gateway to internet for external parties’ communication. IT facilitates the
acquisition, processing, storing, delivery and sharing of information and other
digital content (Robert, 2005).
10
c) Information System (IS)
Basically, IS is a mean by which people and organizations, utilizing technology,
gather, process, store, use, and disseminate information (Robert, 2005).
2.3 Data Model
It is significant to be exposed with available data model types that will later help to
determine the one that suits develop system inventory. There are many ways to store the
information. Each data model type has its unique architecture, capability and purposes.
In this research study, some selected data model types will be discussed for the purpose
of this development PCB Half Populated Subsystem of Management Inventory System.
2.3.1 Database Management System (DBMS)
A database is an organized collection of related data with the objective that the data can
be easily found whenever it is required. A database management system or DBMS
performs numerous functions in organizations, including the storage and retrieval of
data and metadata, the limit and control of redundancy, the support of simultaneous data
sharing, the provision for recovery and security services, the enforcement of business
rules and data integrity, and the improvement of programming productivity (K. Keeton,
December 1998).
Basically, DBMSs can differ widely based on the way a DBMS organizes information
internally. There are four types of data models reflect the logical relationships among
data in a DBMS. They are as relational, network, flat, and hierarchical. Different DBMS
supports different query language. The internal organization can affect how quickly and
flexibly you can extract information.
11
A commonly used database type is RDBMS (Relational DBMS) model. It is a type of
data object (called an entity), which is a person, event, or thing about the collected data,
is described by a table (called a relation) of rows (called tuples) and columns (called
attributes). This relational model provides for logical connections among entities by
including certain unique data in its tables (K. Keeton, December 1998).
2.3.2 Data Warehouse
A database built to support information access. Typically a data warehouse is fed from
one or more transaction databases. The data needs to be cleaned and restructured to
support queries, summaries, and analyses.
According to Vivek R. Gupta, Senior Consultant in a white paper derived from Data
Warehousing with MS SQL, a data warehouse is a structured extensible environment
designed for the analysis of non-volatile data, logically and physically transformed from
multiple source applications to align with business structure, updated and maintained
for a long time period, expressed in simple business terms, and summarized for quick
analysis. Usually the data stored for business analysis is most effectively is separated
from the data in the operational systems (J. L. Hennessy, 1999).
Data warehousing systems are most successful when data can be combined from more
than one operational system. Traditionally, before the evolution of structured data
warehouses, analysts in many instances would combine data extracted from more than
one operational system into a single spreadsheet or a database. The data warehouse may
very effectively combine data from multiple sources applications such as sales,
marketing, finance, and production and also allow the source applications of to be
integrated into the data warehouse incrementally. The primary reason of this
combination is the ability to cross-reference data from these applications. Nearly all
data in a typical data warehouse is built around the time dimension because it is the
primary filtering criterion for a very large percentage of all activity against the data
12
warehouse such as queries for a given week, month, quarter, or a year activity. The time
dimension in the data warehouse also serves as a fundamental cross-referencing
attribute. For example, an analyst may attempt to access the impact of a new marketing
campaign run during selected months by reviewing the sales during the same periods.
The ability to establish and understand the correlation between activities of different
organizational groups within a company is often cited as the single biggest advanced
feature of the data warehousing system (J. L. Hennessy, 1999).
The data warehouse system can serve not only as an effective platform to merge data
from multiple current applications; it can also integrate multiple versions of the same
application. For example, an organization may have migrated to a new standard
business application that replaces an old mainframe-based, custom-developed legacy
application. The data warehouse system can serve as a very powerful and much needed
platform to combine the data from the old and the new applications. Designed properly,
the data warehouse can allow for year-on-year analysis even though the base
operational application has changed.
Today, data warehousing systems provide the analytical tools afforded by their
precursors. But their design is no longer derived from the specific requirements of
analysts or executives and data warehousing systems are most successful when their
design aligns with the overall business structure rather than specific requirements (J. L.
Hennessy, 1999).
2.4 Internet Technologies
Today, Internet has become the most important tool for people to communicate, either
through emails or online chats, and to do research, upload or download software, e-
business, publishing and so on, via a web browser. With internet, communicate 24
hours, wherever and whenever they like.
13
According to Daniel Amor, the internet means a network infrastructure that is built on
certain standards, the internet standards, which are used by all participants to connect to
each other. The specification of the internet protocol (IP) does not specify which type of
information, services or products should be exchanged but it defines how the flow of
information is organized. These specifications reside on a layer above the internet layer
and one of these protocols for the exchange of information is the World Wide Web with
its hyper-text transfer protocol (HTTP). There are other protocols too that enable people
to communicate via email, chat online (IRC) or newsgroups (NNTP). The web offers
the exchange of documents via HTTP which are mainly in HTML format, allowing
browsers to display the content in the correct way (S. S. Parekh, June 1998).
2.4.1 Web Technologies
In order to have an efficient internet communication that has fast response and reliable,
few elements of web technologies need to be explored in finalizing which technology to
be adopted.
a) Portal and Web Site
A portal is a “World Wide Web site that is or proposes to be a major starting site for
users when they connect to the Web or that users tend to visit as an anchor site” (E.D.
Bugnion, 2000). Portals contain lots of content in the form of news, information, links
and many other services. A web site is also a gateway of a company on the internet for
people to view and get information about the company via a URL (uniform resource
locator) that links the user with the web page.
b) Browser
Browser is a tool used to surf the internet. It forms a connection to a web server,
requests a web page, receives it, and brings it onto the computer screen as shown in