(Đồ án tốt nghiệp) improving the management process to optimize spare part costs at bosch vietnam co ,ltd

BỘ GIÁO DỤC VÀ ĐÀO TẠO TRƯỜNG ĐẠI HỌC SƯ PHẠM KỸ THUẬT THÀNH PHỐ HỒ CHÍ MINH GRADUATION THESIS INDUSTRIAL MANAGEMENT IMPROVING THE MANAGEMENT PROCESS TO OPTIMIZE SPARE PART COSTS AT BOSCH VIETNAM CO., LTD Lecturer: Ph D NGUYEN KHAC HIEU Student Name : NGUYEN THI NGOC HAN ID student No : 15124017 SKL005573 Tp Hồ Chí Minh, July 2019 HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS IMPROVING THE MANAGEMENT PROCESS TO OPTIMIZE SPARE PART COSTS AT BOSCH VIETNAM CO., LTD Student Name : NGUYEN THI NGOC HAN ID student No : 15124017 School year : 2015 Major : INDUSTRIAL MANAGEMENT Lecturer : Ph D NGUYEN KHAC HIEU Ho Chi Minh City, July 2019 i HCMC UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS IMPROVING THE MANAGEMENT PROCESS TO OPTIMIZE SPARE PART COSTS AT BOSCH VIETNAM CO., LTD Student Name : NGUYEN THI NGOC HAN ID student No : 15124017 School year : 2015 Major : INDUSTRIAL MANAGEMENT Lecturer : Ph D NGUYEN KHAC HIEU Ho Chi Minh City, July 2019 ii THE SOCIALIST REPUBLIC OF VIET NAM Independence- Freedom-Happiness ******* Ho Chi Minh City, July 2019 GRADUATION THESIS OBJECTIVES Full name: Nguyen Thi Ngoc Han Major: Industrial management Lecturer: Ph.D Nguyen Khac Hieu Start date: Student ID: 15124017 Class: 15124CL1 Phone number: 0375042487 End date: Subject: Improve the management process to optimize spare part costs at Bosch Vietnam Co., Ltd Initial data and documents: From TEF 4.2 department, LOG, Purchasing and website of Bosch Vietnam HcP Plant Content: Find out about the current spare part management procedures applied at Bosch HcP Plant, based on actual work during the internship and make suggestions to improve management activities spare part Product: Thesis Dean Faculty Instructor iii ACKNOWLEDGEMENTS First, I would like to express my deep gratitude to all teachers from the faculty of High quality training and Economics at Ho Chi Minh City university of Technology and Education who have devotedly taught us over the past years The knowledge as well as the skills that I have learned over the years will be a strong foundation for me to build my career path I would like to express my deep gratitude to Mr Nguyen Khac Hieu - Lecturer of Ho Chi Minh City University of Technical Education He has made good orientations and contributions to help me improve the topic in the best possible way Furthermore, I would like to thanks Bosch Vietnam - HcP Plant, TEF4 department for facilitating me to complete my internship at this company In particular, I would like to express my sincere thank you Ms Le Cam Tien for enthusiastically guiding me and helping me quickly integrate into the new environment In addition, I would also like to thanks Mr Nguyen Phuc Tam, my buddy at Intel for his kindness to guide me to access more new software to support my work, give me some ideas to accomplish the thesis Their knowledge supported me a lot to complete this essay Once again, I would like to thank you all teachers and all alumni so much I wish everyone succeeds in life, wish Bosch Vietnam - HcP Plant and Bosch global will grow up Student Name Nguyen Thi Ngoc Han iv DEFINITIONS AND ABBREVIATIONS LOG: Logistic department TEF: Technical function department ETC: Engineering Testing Current Product department FCM : Facility management department CTG: Account controlling department CP/PIR-VN : Purchasing department LOG-VN: Logistic department at RBVN office QMM: Quality department MFG: Manufacture department PM04: Maintain planning module in SAP of TEF PM: Plant manager HoD: Head of department T-code : Transaction code in SAP MRP: Material Requirement Planning RFQ: Request For Quotation R.O.P: Re-order Point MAZE: Maschinenersatzteile (machinery spare parts) PR: Purchasing Requisition PO: Purchase Order ZD: The defected part ZN: The repaired part ZI: The new part Active part : The part has been consumed for recent 01 year Slow moving part : The part hasn’t been consumed for recent 01 year v UC4 Job : Automatic Creation of purchase orders from Requisitions IFAO: List of non-mover items on Excel spare part analyze software Non-mover part : the part hasn’t been consumed for recent year MIGO: update the status of part on system vi LIST OF TABLES Table 1.1 The function for department 12 Table 2.1 Some misconceptions in spare part management 27 Table 3.1 Statistical safety level for spare part 47 Table 3.2 Classifying spare part based on the usage level within 12 months .48 Table 3.3 Flow chart for transfer over stock to overhaul purpose 50 vii LIST OF FIGURES Figure 1.1: Shareholding and Voting Rights of shareholders in Robert Bosch GmbH Figure 1.2: Business sectors in Bosch Group Figure 1.3: Facts and figures about Bosch in Vietnam 2017 Figure 1.4: HcP Plant in Long Thanh-Dong Nai 10 Figure 1.5: Push belt - a product in HcP 15 Figure 1.6: Element 16 Figure 3.1: Flow chart of creation new part process 38 Figure 3.2: Flow chart of Order Process 42 Figure 3.3: Order process for Overhaul and End-user 44 Figure 3.4: Process flow chart for non-mover control 49 Figure 3.5: Process for New part return at Bosch 55 Figure 3.6: Reasons for returning spare parts from PM team 57 Figure 3.7: Spare part cannot found information in system compare to new parts request return (1 Jan to 13 Mar, 2019) 59 Figure 3.8: Quantity and Cost of parts lost 60 Figure 3.9: Fish bone diagram to find out reasons for parts lost 61 Figure 4.1: The return area of spare part staff 67 Figure 4.2: Sample of new part return label in system (up to date 3/2019) 67 Figure 4.3: Labels in real which were filled information by technicians 68 Figure 4.4: No label was stuck as the process 69 Figure 4.5: Interface of WH app (Available spare parts) 70 Figure 4.6: Operation principles for update part by using WH parts app 71 Figure 4.7: Interface for WH app (Set up new part) 72 Figure 4.8: The return area of spare part staff after improvement 73 Figure 4.9: Interface for History Data App 74 viii Figure 4.10: Procedure recording spare part history status 75 Figure 4.11: Procedure order spare part from History Data App .77 Figure 4.12: Procedure return spare part from History Data App 78 ix F03P.200.629 0320.512.635 F03P.104.519 F03C.C72.200 F03P.102.315 0320.514.384 3843.AH6.104 F03P.106.552 F03C.F79.684 F03P.107.773 0320.508.160 0320.507.899 F03P.107.121 F03C.G42.568 0320.505.963 F03P.100.469 F03C.F79.697 F03P.108.279 F03P.105.499 F03P.104.961 0320.509.995 F03P.107.166 0320.509.027 F03P.102.314 F03P.107.134 F03P.108.497 F03P.108.872 F03P.100.710 F03C.F79.983 F03P.105.997 0320.502.107 F03P.106.433 0320.510.964 F03P.102.518 F03P.105.226 F03P.102.584 0320.150.031 F03C.G16.373 F03P.100.710 F03C.F82.338 F03P.102.078 F03P.101.736 F03P.106.537 F03C.F79.194 0320.509.309 F03P.103.078 F03P.108.977 F03P.108.566 F03P.106.540 F03P.102.963 F03C.G09.481 F03C.F47.276 0320.505.160 F03P.102.672 0320.511.653 F03P.200.068 F03P.103.956 F03C.F82.338 F03P.200.558 0320.512.101 F03P.108.806 0320.513.841 F03P.103.048 0320.503.087 0320.512.758 0320.512.759 F03P.102.725 F03P.109.003 F03P.105.710 F03P.107.989 0320.509.449 0320.503.413 0320.503.415 F03P.104.264 0320.503.414 F03P.101.349 F03P.101.090 0320.508.436 F03P.108.339 F03P.104.220 F03P.101.736 F03P.106.852 0320.512.659 F03P.101.736 0320.512.660 0320.512.661 0320.512.658 0320.512.657 F03P.109.515 R345.401.061 R347.602.303 F03P.108.699 F03P.105.884 F03P.106.556 F03P.106.540 F03P.102.672 0320.503.654 F03P.101.019 F03P.106.538 0320.501.196 0320.512.920 F03P.108.046 0320.504.793 F03P.103.210 0320.510.625 F03P.108.743 F03P.200.331 9 10 10 10 10 10 10 10 F03P.106.125 F03P.106.798 F03P.106.996 0320.504.796 10 10 10 10 F03P.102.967 F03P.106.799 10 10 F03P.102.038 F03P.108.781 0320.504.795 F03P.101.960 F03P.105.436 F03C.G30.158 F03P.108.866 F03P.100.887 F03P.105.456 0320.050.919 F03P.109.804 0320.509.990 0320.513.481 F03P.107.451 10 10 10 10 10 10 10 10 10 10 10 10 10 10 F03C.G16.373 10 0320.514.132 F03P.104.451 F03P.102.949 F03P.102.951 F03P.105.504 F03P.109.590 0320.510.848 F03P.102.954 3800.530.531 F03P.104.893 F03P.107.613 F03P.105.011 0320.511.449 0320.514.307 0320.510.848 0320.512.328 0320.510.318 0320.510.691 F03P.105.103 0320.501.690 0320.512.224 F03P.109.728 0320.512.221 F03P.108.467 F03P.109.472 F03P.107.470 F03P.106.094 F03C.F70.359 0320.501.690 F03C.C72.200 F03P.108.744 0320.501.200 F03P.108.851 0320.503.655 0320.513.363 0320.513.841 0320.509.148 0320.501.690 F03P.102.673 F03P.105.341 0320.507.404 F03P.101.168 F03P.108.929 0320.510.690 F03C.G89.036 F03P.107.245 0320.509.449 F03P.100.294 F03P.100.292 F03P.100.287 F03P.101.156 F03P.106.662 F03P.106.422 F03P.102.502 F03P.102.038 0320.512.101 F03P.104.224 F03P.107.320 0320.507.484 0320.508.353 F03P.106.420 F03P.108.506 F03P.108.293 F03P.102.950 0320.501.737 F03P.108.506 F03P.200.655 F03P.109.987 F03P.106.708 F03P.107.455 F03P.500.329 F03P.500.328 F03P.102.725 F03P.109.003 F03P.105.710 0320.150.099 F03P.108.699 F03P.109.414 F03P.108.435 F03P.109.534 F03P.109.539 F03P.107.180 0320.504.407 3843.AH6.105 F03P.200.185 F03P.107.773 0320.505.534 F03P.106.999 F03P.107.001 F03P.106.766 0320.511.730 F03P.107.121 F03P.107.001 0320.507.312 F03P.108.110 0320.504.302 F03P.103.173 F03P.103.702 F03C.F79.499 0320.513.753 11 13-Mar PC NOT USE Appendix 3: Cost for spare part lost from Jan 3, 2019 to Mar 13, 2019 WEEK 1 1 SAP No 0320.510.226 F03P.102.990 F03P.108.988 0320.509.990 Pump; ESHS32-1 EPD-houder AIRDUC PUR 355 JAW COUPLING; PRA cylinder D63 Bosch Rexroth F03P.105.885 2 2 5777000002 0320.510.976 F03P.100.244 F03P.107.749 F03P.105.593 SERVICE KIT CD0 SWITCH; NAD SM Control panel (C Taper pin DIN79 FAN GROUP SCR PUMP; DOSEER G 3 0320.510.485 F03P.106.215 0320.509.820 PROM OPEN RING D.50 CLAMPING RING FREQUENCY CON 0320.514.118 (Same F03P.104 F03P.100.301 Bag filter _ SBF-0 LINIT SWITCH SE 3 F03P.106.302 0320.512.169 24DFT-ZBZ/X 24V HOSE; DN10 L=1 F03P.105.550 CONT LC1D25M7 4 5 F03P.104.299 0320.508.100 0320.500.699 0320.509.312 F03P.104.962 5 5 F03C.G78.992 0320.513.606 0320.501.049 0320.511.152 M3x50 Socket H ADHESIVE STRIP; SEALING RING; O CONTACT; ELEM Through-beam s Bus line cable SA 1160930050 NON-RETURN VA DEEP-GROOVE B REGULATOR; PRO LINIT SWITCH SE F03P.106.302 24DFT-ZBZ/X 24V axis VA Dm8 / L= 6 7 F03P.107.780 0320.509.309 F03P.102.725 F03P.109.003 F03P.105.710 material: 1.4301 PUSH-BUTTON; PVC hose 25 x 4, Hose-DI13 Tarpaulins curtai Precitec Solid Cu 7 F03P.109.515 R345.401.061 F03P.105.884 PS0795.1052272 Toothed belt 25A Deep groove bal 10x19x5 DIN625 Roller of curve se Damon Support roller D= Sensor working r L212-P-J Panaso 8 F03P.106.556 F03P.101.019 F03P.106.538 0320.512.920 F03P.108.046 PVC joint VS-MW 8 0320.504.793 F03P.103.210 GAS METERING SYST Verzorgingseenh SENSOR; LASER A 9 0320.510.625 F03P.108.743 9 F03P.200.331 F03P.106.125 F03P.106.798 F03P.106.996 BAUM Cylinder 536260 resistor BWU164 3843AC9185 SLIDE GUIDE SVC Base emitter C4M Semiconductor f 2A-60H1 9 10 10 10 10 10 0320.504.796 F03P.102.967 F03P.106.799 F03P.102.038 F03P.108.781 0320.504.795 F03P.101.960 F03P.105.436 PRINTED-BOARD AS ELECTRODE; IONISA Sensor 0830100489 Base receiver C4 ET200ECO, conn solid state relay IGNITION BOLT; ZUN Gear Cam Switch IndraDrive R911326 10 F03C.G30.158 10 F03P.108.866 Connecting cable BCC02MJ Balluf Encoder cable 60 00200-K(20305) 10 F03P.100.887 TRuMark 6130 la 10 F03P.105.456 Computer powe 10 10 0320.050.919 F03P.109.804 RW Belt pulley A Jaw 10 0320.509.990 JAW COUPLING; 10 0320.513.481 TENSIONING RO 10 F03P.107.451 Whole set for en 10 F03C.G16.373 MOTOR; Servo M 10 0320.514.132 SWITCH; ULTRAS 10 10 F03P.104.451 F03P.102.949 Coild detected s "Driven axle outf 10 F03P.102.951 "Driven axle outf 10 F03P.105.504 Valve R9005645 10 F03P.109.590 Clamping cylinde 10 10 0320.509.148 0320.050.919 MANIFOLD; MPV RW Belt pulley A 12,822,792,487 VND 108 ... management process to optimize spare part costs at Bosch Vietnam Co. , Ltd” Some objectives in this research General objective: - Evaluation and analysis of processes related to spare parts management. .. UNIVERSITY OF TECHNOLOGY AND EDUCATION FACULTY FOR HIGH QUALITY TRAINING GRADUATION THESIS IMPROVING THE MANAGEMENT PROCESS TO OPTIMIZE SPARE PART COSTS AT BOSCH VIETNAM CO. , LTD Student Name : NGUYEN... according to their consumption 2.2.3 Life cycle of spare part 2.2.4 Spare part inventory 2.2.5 Myths about spare parts management program 2.2.6 Spare part management and other