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
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 : ………
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)
i
ABSTRACT
ii
ABSTRAK
iii
DEDICATION
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.
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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
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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
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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
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
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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
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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
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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.
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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
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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
4
1.6 Chapter Summary
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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.
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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)
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).
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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).
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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
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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
