| 2. Planning and System Controls (PPC & Supply Chain) |
- Integrated Systems: The planning process is managed through CMS (Card Management System) and SAP (Material Requirement Planning software).
- Production Orders: PPC (Production Planning & Control) runs Material Resource Planning (MRP), creates a Bill of Material (BOM), and raises Production Orders based on customer requirements and inventory.
- Inventory Security: Raw material and devices are compiled at the Raw Goods Warehouse (RGWH) under the auditable Four-Eyes Principle (4EP) and verified by a QC representative before being issued to production.
- Sterilization Protocol: The production area and machines are subjected to a sterilization process by the Production Manager after one production order is complete and before starting a new one. New production only starts after the previous Sales Order (SO) has been closed and machines are sanitized.
|
| 3. Asset and Security Controls |
- Locked Transport & Storage: Material is transported to the production floor in locked trolleys, each carrying a visible adhesive pocket containing the production order and reconciliation sheet.
- WIP Security & Key Management: Locked trolleys are used for temporary storage of Work-in-Process (WIP) or uncontrolled assets such as card bodies for trials.
- Combination Locks: Production, QC, and Warehouse personnel use combination locks for securing their WIP. Lock codes are changed quarterly, with the Senior Manager PPC serving as the custodian of the codes record.
|
| 4. Quality Control and Validation |
- Pre-Production Trials: For core processes (OS Loading, Glue Tape Lamination, Milling, Embedding, Punching), a small test batch or trial run is conducted first. This batch must be checked, tested, and mutually approved by Production, IT, and QC before bulk production begins.
- Final Quality Check (QC): QC is performed on the accepted cards according to the Approved Quality Plan.
- Final Count and Packing (4EP): The final count of cards, carton packing, and shrink-wrapping are completed under auditable 4EP (Four-Eyes Principle), involving two authorized personnel.
|
| 5. Rejection and Destruction |
- Quarantine Process: A lockable quarantine cabinet is maintained in the final QC area to isolate rejected Class-1 assets until re-makes are created and replaced. The QC Engineer acts as the custodian.
- Reconciliation & Destruction: Reconciliation is performed after personalization. Final destruction of rejected assets follows the approved Rejection Control and Destruction Process.
|
| 6. Receiving and Storage of Finished Goods |
- Designated Area: A specific area inside the Finished Goods Warehouse (FGWH) is allocated for storing finished goods.
- Verification: Upon receipt from production, carton labels (from the QC tool and SAP) are checked against the delivery documents (packing list or production report).
- Physical Inspection: The physical condition of the received goods is inspected for damage or discrepancies, and findings are documented.
- Floor to Listing Methodology: The warehouse team scans the cartons, and data is automatically populated as a Goods Dispatch Note (GDN) in CMS.
- Inventory Accuracy: SAP inventory records are matched against received quantities before allocating storage locations.
|
| 7. Order Picking and Packing |
- Prioritization: Customer orders are prioritized based on urgency and delivery deadlines.
- Verification: The required quantity is picked from designated storage locations and checked against the order details.
- Secure Packing: Items are packed securely to ensure safe transit and prevent damage.
|
| 8. Dispatch and Security |
- Document Generation: All required shipping documents—including GDN and Delivery Challan (DC)—are generated from CMS and SAP.
- Security for Transit: Finished goods are transported in a van accompanied by a security guard.
- Simultaneous File Delivery: The output file must be delivered along with the goods. Logistics coordinates with the SPDM team to ensure timely delivery.
- Proof of Delivery: The customer signs both the GDN and the Delivery Challan upon receiving the goods.
- Sales Order Closure: The finance department issues the invoice after customer receipt is confirmed, officially closing the Sales Order (SO).
- Communication: An official email is sent confirming the delivery schedule, and all delivery details are updated in the CMS.
|
