Traceability System for Quality Assurance on Make to Order Products

Transcription

1 Proceedings of the Asia Pacific Industrial Engineering & Management Systems Conference 2014 Traceability System for Quality Assurance on Make to Order Products Iwan Vanany Department of Industrial Engineering Institut Teknologi Sepuluh Nopember (ITS), Surabaya, Indonesia Tel: (+62) , Nur Aini Rahmawati Department of Industrial Engineering Institut Teknologi Sepuluh Nopember (ITS), Surabaya, Indonesia Tel: (+62) , Abstract. For manufacturing sectors especially make to order type, highly service level for customers is important objectives to be achieved. Many manufacturing companies used the quality assurance to ensure the quality products that are required by customers can be manufactured by companies using material, spare parts and process machine recommended. However, a few previous studies used traceability system to support the quality assurance system on make to order products types. The traceability system a good way to verify the material and spare parts used in products and type of processes and machines done. The proposed QA traceability system for power plant manufacturing company was developed based on web services to enhance the quality assurance system as case study in this research. The architecture and design of the traceability system was provided using Unified Modeling Language (UML). Based on these models, the software was developed by open source cross-platform development. It uses the data captured through quick response (QR) label with barcode readers and wireless infrastructure. The users in case study are selected to identify the expected benefits of system and evaluate the system by interviews and questionnaires. The results indicate that a new traceability system can provide the beneficial for company (reducing claims, reusable waste materials and reducing over stocks) and customers (reducing monitoring costs). Keywords: Traceability system, quality assurance, and make to order products. 1. INTRODUCTION The traceability system is widely applied in various industries to make different products not only for food products (fish (Abad et al, 2009), fruits (Manos and Manikas, 2010), beef (Loureiro and Umberger, 2006, Shanahan et al, 2009,)) but also in manufacturing products such as food processing (Moe, 1998), automotive (Robson et al, 2009), and aircraft products (Harun et al, 2008). In manufacturing industries context, traceability system is used to trace from spare parts or material in spare parts or raw material until finished product. Many experts believe that the main objectives of traceability implementation are supporting systems in companies to ensure products are safe and good quality. Galvao et al (2010) believe that traceability system is not only a way to ensure food safety but also quality of spare parts or raw materials required and processing machine recommended. Aung and Chang (2014) also argue that good traceability system is potential to minimize unsafe and poor quality products on food supply chain. Within the make to order products, main objective of traceability implementation that should be achieved is increasing the quality products. Generally, the quality requirements of products have been ascertained before the product is produced. Moe (1998) and Aung and Chang (2014) declared that the quality assurance/management is able to be upgraded with the traceability system as one of the sub-systems. Moe (1998) pointed out that traceability system is important subsystem of quality assurance/ management. Aung and Chang (2014) mentioned that traceability system is 1 130

2 essential sub system in addition to Good Manufacturing Practices (GMP) and Hazard Analysis Critical Control Point (HACCP). Regattieri et al (2007) believe that traceability system is a tool to meet quality requirement and to connect relationships between producer and customers. In make to order products, its possibility if traceability system can support quality assurance implementation as way to reduce mistake spare parts required and processing recommended in make to order products. In previous studies, a few studies to investigate traceability in manufacturing. Moe (1998) investigated the perspective on traceability system in food manufacturing. Jansen-Vullers et al (2003) designed the information systems for traceability using Gozinto graph modeling to present a graphical listing of raw materials, spare parts, intermediates and subassemblies. Harun et al (2008) discussed some issues including real time traceability system using radio frequency identification (RFID) in aircraft part manufacturing. Robson et al (2007) used traceability to efficiently and automatically spare parts in automotive industry. As we know, a few studies developed traceability system to support quality assurance implementation in manufacturing companies especially for make to order products. This paper developed traceability system software based on web services in power plant manufacturing as case study. 2. QUALITY ASSURANCE TRACEABILITY MODEL 2.1. Description The main objective of quality assurance on make to order is to ensure the materials/parts used and pre and fabrication processes executed had been appropriate with project/customer requirements. The results of inspection and test on pre-fabrication and fabrications process will become evidence whether materials/parts used and process executed appropriate or not with project requirement. Quality assurance process is started from receiving material/parts until shipping to customer. The company must be reported the end of manufacturing when deliver final products to customer. The customers have rightful authority to reviews the inspection and testing documents. They also be able the witness to direct inspect materials/parts used and processes executed. Moreover, the customers also can hold the projects if the quality materials/parts and fabrication process is not appropriate with project requirements. Third parties are engaged to support quality assurance such as ASME inspector, ISO inspector and manpower department etc. The quality control section is also well serve to verify and check whether the process of prefabrication and fabrication in accordance with the project requirement. The production department will be assisted with the qualify procedure manuals that have been standardized in order to pre-fabrication and fabrications can produce the good quality process. We believe that the traceability system can support the quality assurance on the make to order products. If there is a problems in a production site, the employee may soon be in tracking where the material and process what is causing the problem. Using the online-based software, the employees will easy to make the review document in the progress the project and the end of the manufacturing reports in the end of project. The consumer can also easily to review the documents in progress project without come to production site Business Process and Information Flows Business process mapping and information flows are the main activities research that should be carried out to develop traceability system software for quality assurance on make to order products. We develop the business process of traceability system was mapped based on interview with quality assurance/quality management (QA/QM) manager. The information flow of data and type of transportation was also identified using observations, interview with staff and collection QA/QM documents In Figure 1, the business process and information flows for quality assurance on make to order products are depicted. The activities that take make at companies that diversified a make to order are divided into four subprocesses such as receiving materials in warehouse, prefabrications, fabrications, and assembly and final inspections. Good receipt sheet Material and spare parts sheet Pre-fabrication quality sheet quality sheet End of Manufacturing Report Suppliers warehouse Pre-fabrications s Assembly and final inspections Customers truck foklift foklift ship Figure 1: The business process and information flow for quality assurance on make to order products 2 131

3 There exist two flows that need to be described as the product flows and document flows. Product flows describe how the flow of units of flows and the process whereby the consumer will conduct inspections in accordance with the agreement made. The type of transport used is also informed on its product flow in the event of displacement. Document flows are used to determine what is happening and be prepared. Good receipt sheet is a document that is required to report the receipt of materials from the suppliers. Dispatch sheet is a progress report which informs the work following it s testing on each sub-process. Some types of dispatch sheets are the material and spare parts sheet, prefabrication quality sheet, and fabrication sheet. Whereas the manufacturing end of the sheet is a final report to be done to the consumers. 3. QUALITY ASSURANCE TRACEABILITY SYSTEM 3.1 Architecture System The architecture of traceability system is shown in figure 2 and can be divided into two main systems such as traceability system and database server. The first main TRACEABILITY SYSTEM system is the set of application s and the second system serve the traceability database in the server. The first comprises of automation identification (auto-id) technology is used to capture data as entry data to system using quick response (QR) tags, fixed or mobile readers, and antennas. The second is software was developed to support quality assurance for make to order products using open sources cross-platform development. The third is model that consist two models such as quality assurance model and inventory model. The historical project documents are created by the system in order to support quality assurance model. Some important information in historical project documents is resulted such as (1) type and brand of spare part used, (2) when processes each stage get started and finished, (3) what quality of processes required and (4) when the project is accepted. For inventory model, how many raw material and work in process (WIP) still exist. Finally, the function is used to provide information collection each project, quality assurance documents, and inventory documents especially for raw material and work in processes still exist. SERVER Function Information collection QA support Inventory model SQL server Model Quality assurance model Inventory (Raw material and WIP) model HTTP online Software Web Service SQL server Auto_ID QR code Traceability Database Figure 2: The architecture of traceability system for quality assurance proposed 3.2 Usage Requirements Model Wu et al (2006) pointed out that Use Case Diagram in UML is a useful approach to capture operation flows and requirements of system functions. Lee and Xue (1999) also believe that the main advantage of use case analysis is that it helps manage the complexity of systems. The Use Case Diagrams are closely connected between actors and systems (use case and system boundary). Figure 3 shows the Use Case Diagram for traceability system for quality assurance in make order products. Each use case in systems is defined as follows: Record raw material and spare parts inventory: warehouse department would record material and spare parts received and would insert by ID striker. The users request materials and spare parts required by the 3 132

4 pre-fabrication and fabrication departments shipped by warehouse department. The user gives his request to buy the spare parts and materials needed in accordance with the bill of materials of products to be created. warehouse employee Pre-fabrication employee Traceability System Record material and spare parts inventory Record pre-fabrication process Record fabrications process Develop quality assurance documents Customers 3.2 Traceability Software Based on design of traceability system using UM developed, traceability software was developed by open source cross-platform development. With open source development, the functions of quality assurance (QA) traceability system were implemented such as system setup, quality assurance modules and tracing. In system setup, database name, user name and password and others was set up in this software. Quality assurance modules were developed based on business processes and entities of business processes such as (1) warehouse, (2) prefabrication, (3) fabrication, and customers. Traceability software developed provided the tracing menu each user. In figure 4, the interfaces of quality assurance traceability software especially main menu and warehouse module were shown. employee Record waste material inventory Figure 3: The use case diagram of traceability system for quality assurances Record pre-fabrications process: The results of inspection and testing for the pre-fabrication process are recorded by pre-fabrication department and are also reported to the consumer. To work in process of prefabrication process that does not pass the testing and inspections prior to rework process. Record fabrications process: Similar with the prefabrication department, the testing results for the process are also recorded to indicate that quality in accordance with customer requirements. If it turns out the testing results are not in accordance with the required standards, it is necessary to rework and record. Comply with a request quality assurance documents: some documents related to quality assurance required by the consumers need to be made and reported. The documents required are (1) material/spare parts used sheets, (2) pre-fabrications sheets, (3) fabrication sheets, and (4) end of manufacturing reports. Waste material inventory. The waste materials that can still be used, it should be noted and stored in the warehouse. The waste material resulting from the process of pre-fabrication and fabrication should be reshipped to the warehouse location. (a) Main menu (b) Warehouse module Figure 4: interface of traceability system for quality assurance (a) main menu (b) warehouse module 4 RESULTS AND DISCUSSIONS 4.1. Testing in Case Study The traceability system testing has been performed at the manufacturing company that was producing power plant equipments such as boilers. In the case study 4 133

5 company, the pilot was developed in boilers sections and separate with existing systems to avoid the disruptions of existing work. Figure 5 depicts the business process in all stages of the supply chain which consists of material and Raw material and components warehouse Pre-fabrication spare parts suppliers, warehouse, pre-fabrication, fabrication assembly and inspection departments, and industrial customers. Assembly and Inspection Header Pipe Pre- Header Pipe Assembly Suppliers End Plate Pre- End Plate Final Inspection storage Lug Pre- Lug Moving Final product storage Customers Nozzle Pre- Nozzle Moving Shipping Moving Figure 5: The business process and information flow in pilot case study Note: 1 = poor, 2 = acceptable, 3 = good, 4 = excellence Figure 6: The results of evaluation for QA traceability model and software 5 134

6 The activities at warehouse are receiving the raw materials and spare parts purchased, storing and transporting to department required. Pre-fabrication consists of receiving, processing needed (header pipe, end - plate, lug, and nozzle pre-fabrication) and moving to fabrication department. The activities at fabrications are continuation process of pre-fabrications that consist of receiving work in pre-fabrication process, fabrication processing needed (header pipe, end-plate, lug and nozzle fabrications) and moving to final assembly and inspections. In assembly and inspection process, the activities should be conducted are assembling and inspection for finished products. During the testing for 2 boilers projects in case study, all the processes for the projects on boiler sections have been performed and controlled. Semi structure questioners and interviews were used to verify models and traceability system software. Four respondents (QA manager, head of pre-fabrications, fabrications, and warehouse) were filled the semi-structure questionnaires and give their opinions when interviewed. The results of evaluation for QA traceability model and software by questionnaires are depicted in figure 6. It can be seen from figure 5 that most respondents considered the QA documents on software are complete. Two respondents considered the QA documents were excellent and two respondents considered it was good. For three factors such as the business process of model, QA traceability model, and applicability of QA traceability system, one respondent considered the factors were excellence and three respondents considered it were good. Menu software is relatively complete. Three respondents considered completeness of menu software were good and one respondent considered it was acceptable. However, two factors were relatively acceptable by respondents such as the suitability of code product and shipping labels (one respondent considered it was good and three respondents considered it were acceptable) and the easy to use of software (all respondents considered it were acceptable) Cost- Benefits Analysis Some experts are using the cost-benefits analysis to evaluate the model and implementation of traceability (Chryssochoidis et al. (2009), Karlsen et al. (2010)). Value of the B/C ratio exceeds 1 means more benefits than costs incurred to create and implement a new traceability system. Determination of the expected benefits is difficult. In this study, the determination is based on the discussions and interviews two periods with the quality assurance managers. The expected benefits of traceability implementation can be obtained to implement the company and its customers. Benefits for the company is (1) reusable waste material, (2) reducing claims, (3) reducing the over stocks of materials and spare parts. While the benefits to consumers as the owner order is reducing monitoring costs for customers. The cost required to implement the system are (1) the software costs, (2) equipments such as barcode printers, readers and stickers, (3) hardware such as networks, operations and maintenance costs and repair costs such electrical costs), and (4 ) training. The results of the cost-benefits analysis for QA traceability system was calculated in table 1. It can be seen the ratio B/C total is greater than 1 (1.27 point), which indicates that the expected benefits that can be received by the company and the consumers are greater than the cost total that were spent. Hence, the QA traceability system is positive to be developed and implemented. The ratio B/C company (0.77) compared with the B/C consumers (0.50) shows that the expected benefits obtained by the company higher than the benefits gained by consumers. Table 1: The results of the cost-benefits analysis ITEMS Two projects ($) I. Expected Benefits A. Company benefits Reusable waste material 3,500 Reducing claims 1,500 Reducing over stocks 3,000 Sub Total 8,000 B. Customers benefits Reducing monitoring costs - reduce monitoring frequency (1 trips x 4, ,000) - reduce durations of stay (1 trips x 2 1,200 persons x Sub Total 5,200 TOTAL BENEFITS 13,200 II. Costs Software programmers 5,000 Equipment supports - barcode printer (1 US 500) barcode readers (4 200) barcode stickers (4 25) 100 Hardware (LAN networks) 1,000 Operations and maintenance costs (elect 1,000 rical costs, etc) Training 2,000 TOTAL COSTS 10,400 B/C (Company) 0,77 B/C (Customers) 0,50 B/C (Total) 1,

7 5. CONCLUSSIONS The development of traceability system for quality assurance provided significant opportunity to support the quality assurance activity in make to order company. The QA traceability system added more functions to deliver better quality assurance activity. Based on evaluation by users in company and compared with the manual system, it achieves the completeness of QA documents that should be reported to their customers. It also facilitates a cross communication information flow between among departments in company (warehouse, pre-fabrication, fabrication and final assembly and testing) and their customers. The main findings of this study are the new expected benefits that can be obtained not only for the company but also for their consumers. Their consumers can reduce the monitoring costs that are given by the reducing the duration of the visit and stay. The expected benefits that are gained the company is not only related with the quality assurance as reducing claims but is also able to provide expected benefits to the inventory aspects (reducing over stocks and reusable waste material). Based on cost-benefits analysis, it is positive to be developed and implemented because the expected benefits that were gained are greater than the total costs that were spent. The application of QA traceability system has been conducted in one case study. The results indicate that model is more expected benefits can be gained and provide management with a potentially powerful QA traceability tool. However, the extend studies in various types of manufacturing sectors and products will be conducted to enhance the system and software. It is also provide a better insight into the limitations of system and the way it could be changed for traceability system for quality assurance on make order products REFERENCES Abad, E., Palacio, F., Nuin, M., Zárate, G. D., Juarros, A., Gómez, J. M., et al. (2009). RFID smart tag for traceability and cold chain monitoring of foods: demonstration in an intercontinental fresh fish logistic chain. Journal of Food Engineering, 93(4), Aung, M. M., & Chang, Y. S. (2014). Traceability in a food supply chain: Safety and quality perspectives. Food Control, 39, Chryssochoidis, G., Karagiannaki, A., Pramatari, K., & Kehagia, O. (2009). A cost-benefit evaluation framework of an electronic-based traceability system. British Food Journal, 111(6), Galvão, J. A., Margeirsson, S., Garate, C., Viðarsson, J. R., & Oetterer, M. (2010). Traceability system in cod fishing. Food Control, 21(10), Harun, K., Cheng, K., & Wibbelmann, M. (2008). RFIDenabled aerospace manufacturing: theoretical models, simulation and implementation issues. Paper presented at the Industrial Engineering and Engineering Management, IEEM IEEE International Conference on. Jansen-Vullers, M. H., van Dorp, C. A., & Beulens, A. J. (2003). Managing traceability information in manufacture. International Journal of Information Management, 23(5), Karlsen, K. M., Olsen, P., & Donnelly, K. A.-M. (2010). Implementing traceability: practical challenges at a mineral water bottling plant. British Food Journal, 112(2), Loureiro, M. L., &Umberger,W. J. (2006). A choice experiment model for beef: what US consumer responses tell us about relative preferences for food safety, country-of-origin labeling and traceability. Food Policy, 32, Manos, B., &Mnikas, I. (2010). Traceability in the Greek fresh produce sector: drivers and constraints. British Food Journal, 112(6), Moe, T. (1998). Perspectives on traceability in food manufacture. Trends in Food Science & Technology, 9(5), Robson, C., Watanabe, Y., &Numao, M. (2007).Parts traceability for manufacturers.in IEEE Proceedings of the 23td International Conference on Data Engineering, Istanbul, Turkey, Regattieri, A., Gamberi, M., & Manzini, R. (2007). Traceability of food products: General framework and experimental evidence. Journal of food engineering, 81(2), Shanahan, C., Kernan, B., Ayalew, G., McDonnell, K., Butler, F., & Ward, S. (2009).A framework for beef traceability from farm to slaughter using global standards: an Irish perspective. Computers and Electronics in Agriculture, 66(1),