A PRODUCT CLASSIFICATION AND PRODUCTION
TRACEABILITY SYSTEM FOR WOMEN SILVER JEWELRY
PRODUCTS
By
Achara Satayapaisal
SIU THE: SOM-MSM-2007-06
A PRODUCT CLASSIFICATION AND PRODUCTION
TRACEABILITY SYSTEM FOR WOMEN SILVER JEWELRY
PRODUCTS
A Thesis Presented
By
Achara Satayapaisal
Master of Science in Management
School of Management
Shinawatra University
October 2007
Copyright of Shinawatra University
Acknowledgments
The author is very grateful to Shinawatra University for the Master of Science
in Management (MSM) degree scholarship and the Thailand Research Fund (TRF) for
this thesis study funding.
Throughout the period of performing this thesis, the author has been very
grateful to many people. First of all, I would like to express my sincere gratitude to
my advisor, Assoc. Prof. Dr. Chuvej Chansa-ngavej who advised and contributed me
from the start till the completion of this thesis, always gave me valuable knowledge
and guidance, and encouraged me to complete this thesis. I would like to express my
gratitude to my committee members, Assoc. Prof. Dr. Supachok Wiriyacosol, Dr.
Amporn Soongswang and Asst. Prof. Dr. Manop Reodecha who gave me valuable
suggestions and corrections for my thesis. I would like to express my gratitude to the
gemology experts, Asst. Prof. Siwaporn Sahavat and Arjarn Suree Likittachai who
gave me some basic knowledge of gemology. I would like to express my gratitude to
Dr. Robert John Kirkpatrick and Ms. Elizabeth Jane Reynolds who gave me the
valuable English language consulting.
Most importantly, I would like to give special gratitude to my parents, my
husband and his parents for their love, understanding, and providing support for me to
complete this thesis.
Finally, I would like to express my gratitude to all the other people, who
helped me to carry out this thesis, although their names are not stated here.
i
Abstract
Mass production of exported jewelry is a labor intensive industry that adds
value to the Thai economy and increases employment. The Thai jewelry industry is
characterized mainly by small- and medium-scale enterprises (SMEs). A common
practice of jewelry SMEs is to have parts of the production process outsourced to
nearby communities, therefore, making it crucial to have a quality control system in
place. To be able to control the jewelry product quality of the company and
outsourcers, a product classification and production traceability system was developed
for tracing the process route of the jewelry product. The product classification and
production traceability system in this thesis was developed in tandem with a case
study company that manufactures fashionable sterling silver jewelry for girls and
young women. The main products are earrings and nose jewelry. The product
classification was developed by creating a coding system for the product and its parts
(or materials), based on a mixed code (or hybrid structure) using the group technology
classification and coding theory. The developed coding was alphanumeric and every
digit(s) had a meaning that could explain the design attributes (such as shape, color,
material and so on) and manufacturing attributes (such as major process, finishing
surface) of a product and its parts (or materials). The production traceability system
was developed according to the purposes of the case study company based on the
company requirements and problems they were facing. The result of this thesis is a
prototype product classification and production traceability system for mass producers
of fashionable women’s sterling silver jewelry that is beneficial to trace back to
product historical data which leads to reduced extra costs and extra processes from
recycling suspected products and improve product quality. This prototype could be
used as a guideline for other jewelry businesses for adapting their manufacturing
process.
Keywords:
Product classification
Production traceability
Women silver jewelry
Thai jewelry
ii
Table of Contents
Title
Page
Acknowledgments
i
Abstract
ii
Table of Contents
iii
List of Figures
v
List of Tables
vii
Chapter 1 Introduction
1
1.1 General
1
1.2 Statement of the Problem
2
1.3 The Objectives of the Study
2
1.4 The Expected Outcome
2
1.5 Scope of Study
2
1.6 Research Methodology
2
1.7 Definitions of Terms
3
Chapter 2 Literature Review
4
2.1 Overview of Thai Jewelry Industry
4
2.2 Gems
8
2.3 Jewelry Production
9
2.4 The Case Study Company: Sterling Silver Jewelry
10
2.5 The Overview of Production Traceability
14
2.6 Product Classification
15
2.7 Product Classification of Jewelry
15
2.8 Method for Developing the Product Classification and
Coding System
22
2.9 Method for Developing the Production Traceability System
Chapter 3 Research Methodology
30
31
3.1 Introduction
31
3.2 Data Collection for Studying Products and Processes in
the Case Study Company
31
iii
3.3 System Development
33
3.4 Field-Test
33
3.5 System Adjustment
33
Chapter 4 Development and Application of the System
34
4.1 The Collected Data
34
4.2 Development of Product Classification and Coding
42
4.3 Development of Production Traceability System
66
4.4 Result of System Application and User’s Satisfaction
76
4.5 Recommend Action for Further Software Development
in the Case Study
78
Chapter 5 Conclusions and Recommendations
79
5.1 Summary and Conclusions
79
5.2 Research Difficulties and Limitations
79
5.3 Recommendations for Further Development
80
References
81
Appendics
84
Appendix A Interview Guidance: Company Management
and Employees
84
Appendix B Interview Guidance: Gemology Expert
85
Appendix C Example of Rhinestone Color Code
86
Appendix D The Standard Rhinestone Size
87
Biography
89
iv
List of Figures
Title
Page
Figure 2.1 The Top Five Ranking of Thai Jewelry Exports Value by Country
6
Figure 2.2 The Top Five Ranking of Thai Gold Jewelry Exports Value
by Country
6
Figure 2.3 The Top Five Ranking of Thai Silver Jewelry Exports Value
by Country
7
Figure 2.4 The Market Share of Silver Jewelry Import into the USA Market
in 2002 - 2006
7
Figure 2.5 The Market Share of Jewelry Import into the USA Market in
Year 2006
8
Figure 2.6 The Draft Organizational Chart of the Case Study Company
11
Figure 2.7 Silver Tubing Process in the Case Study Company
11
Figure 2.8 Silver Stamping Process in the Case Study Company
12
Figure 2.9 Silver Casting Process in the Case Study Company
13
Figure 2.10 Example of Monocode (Hierarchical Structure)
25
Figure 2.11 Model Structure of Mixed Code (Hybrid Structure)
26
Figure 2.12 The Basic Structure of Opitz Coding System
27
Figure 2.13 Form Code (Digits 1 to 5) for Rotational Parts in the Opitz Coding
System
28
The Methodology used in this Thesis
31
Figure 4.1 Main Process Flow in the Case Study Company
39
Figure 4.2 Silver Tubing Process Flow in the Case Study Company
40
Figure 4.3 Silver Stamping Process Flow in the Case Study Company
40
Figure 4.4 Silver Casting Process Flow in the Case Study Company
41
Figure 4.5 Silver Pin Making Process Flow in the Case Study Company
42
Figure 4.6 The Structure of Product Families
43
Figure 4.7 The Developed General Coding Structure
43
Figure 4.8 Developed Finished Goods Coding Structure (Translated from Thai)
45
Figure 4.9 Developed Jewelry Coding Structure (Translated from Thai)
47
Figure 4.10 Developed Card Coding Structure (Translated from Thai)
50
Figure 3
v
Figure 4.11 Developed Semi-Jewelry Coding Structure (Translated from Thai)
52
Figure 4.12 Developed Accessory Coding Structure (Translated from Thai)
53
Figure 4.13 Developed Ornament Coding Structure (Translated from Thai)
56
Figure 4.14 Developed Material Coding Structure (Translated from Thai)
58
Figure 4.15 Developed Label and Sticker Coding Structure (Translated from Thai) 59
Figure 4.16 Developed Packing Material Coding Structure (Translated from Thai) 61
Figure 4.17 Products Coding Main Menu
62
Figure 4.18 Finished Goods (Family “A”) Menu
62
Figure 4.19 Jewelry (Family “B”) Menu
63
Figure 4.20 Card (Family “C”) Menu
63
Figure 4.21 Semi-Jewelry (Family “D”) Menu
64
Figure 4.22 Accessory (Family “E”) Menu
64
Figure 4.23 Ornament (Family “F”) Menu
65
Figure 4.24 Material (Family “G”) Menu
65
Figure 4.25 Label and Sticker (Family “L”) Menu
66
Figure 4.26 Packing Material (Family “P”) Menu
66
Figure 4.27 Developed Traceability Recording Form (Main Process)
(Translated from Thai)
69
Figure 4.28 Developed Traceability Recording Form (Tubing Process)
(Translated from Thai)
70
Figure 4.29 Developed Traceability Recording Form (Stamping Process)
(Translated from Thai)
71
Figure 4.30 Developed Traceability Recording Form (Casting Process)
(Translated from Thai)
72
Figure 4.31 Developed Traceability Recording Form (Packing Process)
(Translated from Thai)
73
Figure 4.32 Developed Traceability Recording Form (Pin Making Process)
(Translated from Thai)
74
Figure 4.33 Data Storage Control Form (or Record Control Form)
76
Figure 4.34 The Company Executive Rating Score
77
vi
List of Tables
Title
Table 2.1
Page
Export Value of Thai Industrial Goods, Year 2004 to 2007
(January - May)
5
Table 2.2
Examples of Design Classification for Jewelry
Table 2.3
Examples of Design and Manufacturing Attributes included in a
Classification and Coding System
16
23
Table 4.1 The Case Study’s Documentary Information
34
Table 4.2
Example of Finished Goods Code: “A-B001-00001”
44
Table 4.3
Example of Jewelry Code: “B-BA-Z001-BO-CA1COO”
46
Table 4.4
Example of Card: “C-BOOB01-010”
49
Table 4.5
Example of Semi-Jewelry: “D-AB-Z001”
51
Table 4.6 Example of Accessory: “E-BBA-020”
53
Table 4.7
Example of Ornament: “F-BA1P04-A01-002”
55
Table 4.8
Example of Material: “G-AAO-030”
57
Table 4.9
Example of Label and Sticker: “L-A073528-040”
59
Table 4.10 Example of Packing Material: “P-FB-010”
vii
60
Chapter 1
Introduction
1.1 General
Mass production of jewelry for export has become an important source of
income for Thailand. The jewelry industry is one of the top ten ranking industries that
produces added value to the Thai economy and increases employment. It is essential
for the industry to be cost-competitive against competitors such as Hong Kong, China,
and India. The jewelry industry is a labor intensive industry, and relies heavily on the
craftsmanship and skills of workers that may not be substituted by machines.
However, some competitors, such as China and India, have lower labor costs, thus it
is difficult for Thai jewelry to be cost competitive by reducing labor costs. The
highest value market that Thai jewelry exports to is the USA. Previously Thai jewelry
costs could compete with low labor cost countries that export to the USA market
because Thailand had eligibility under the GSP (Generalized System of Preferences)
that allowed tariff exemptions. Nowadays Thai jewelry exporters face a huge problem
as the USA GSP will be cut. Losing GSP benefits will produce a significant effect on
Thai jewelry competitiveness. Having a competitive advantage in terms of time-tomarket and attractive design of the products is also a necessity. At present, such
industry in Thailand is characterized mainly by small- and medium-scale enterprises
(SMEs) often operated by traders turned designers and manufacturers. To ensure
shorter time-to-market, it would be desirable to have shorter design turnaround time,
while having a larger variety of product designs for customers to choose from. To
keep the costs down, a common practice is to have parts of the manufacturing process
outsourced to nearby communities, thus making it crucial to have a quality control
system in place. To be able to control product quality of the company and
outsourcing, it is necessary to track the process route of the jewelry product, and
hence a product classification and production traceability system should be
developed.
1
1.2 Statement of the Problem
This thesis aims to develop a product classification and production traceability
system of a case study company. The company is a small sterling silver jewelry
enterprise that many manufacturing processes’ parts are outsourced.
1.3 The Objectives of the Study
1) To develop a system of coding for product design classification.
2) To use the developed coding system in the manufacturing processes such
that the product lots can be traced back by their historical data, so that the
company can take appropriate control measures. The company will then
benefit from reduced costs, shorter time-to-market, or higher product
quality.
1.4 The Expected Outcome
1) A prototype of a product design classification and production traceability
for mass producers of inexpensive jewelry, especially silver jewelry, for
export will be established.
2) The developed product classification and production traceability system
could be used as a guideline for others’ jewelry businesses.
1.5 Scope of Study
This thesis will concentrate on a women’s silver jewelry manufacturer that
produces silver jewelry products, which may be decorated with synthetic gems, paint,
crystal and others.
Traceability within the scope of this thesis is the production traceability. No
material testing will be carried out.
1.6 Research Methodology
The case study company’s products and production processes have been
collected and analyzed by visiting the factory and interviewing the people concerned.
The product classification system is developed in the form of a product coding
system. The information needed for production traceability is identified and recorded
for product historical data searches. The developed system is field tested for practical
use.
2
1.7 Definitions of Terms
Classification: the division of parts into classes based on their differences or
the combining of parts into classes based on their similarities. Classes should be
exhaustive (cover all parts) and exclusive (each part assigned to one and only one
class) (Britton, 2000).
Coding: the process to assign symbols to the parts or products. Form of
symbols can be numeric, alphabetical or alphanumeric (Anlağan, 1996; Britton,
2000).
Generalized System of Preferences (GSP): a program designed to promote
economic growth in the developing world, provides preferential duty-free treatment
for products from designated beneficiary countries and territories, including leastdeveloped beneficiary developing countries (Office of the United States Trade
Representative [OUSTR], 2007).
Part Family: a collection of similar parts that share specific design and/or
manufacturing characteristics (Tatikonda & Wemmerlöv, 1992).
Production Traceability: the ability to uniquely identify (such as product
details, information on location) and find the route that a product was processed in the
particular points or stages in production that consists of a chain of interrelated events
(Juran & Gryna, 1988; Traceability, 2007).
Rhinestone: rhinestones are colorless or colored artificial gemstones that
simulate diamonds and other gems. They can be made of glass or paste, but the best
rhinestones are cut from quartz crystal. Rhinestones have a fused, metallic backing
that reflects the light and gives the stones fire (Wickell, 2007).
Synthetic gems: synthetic gems are man-made gem products that can be exact
copies of natural gems, or unique materials which are not found in nature. One type of
synthetics is artificial gems which are manufactured to imitate the other gems
(Gemstone, 2007; Smigel, 2007). The term “synthetic gems” used in the case study
was the artificial gems.
3
Chapter 2
Literature Review
This chapter includes a review of the case study’s production processes and
products that are relevant to this research as well as a review of relevant literature,
especially addressing the Thai jewelry industry, classification and coding, production
traceability.
2.1 Overview of Thai Jewelry Industry
In the past, Thailand was one of the world’s leading countries in gemstone
resources, especially rubies and sapphires. The traditional knowledge and high skill
about cutting and processing gemstones turned Thailand into a place for jewelry trade.
The downstream jewelry industry that supports the gem industry has also grown and
Thailand is the world’s leader in jewelry products.
The Thai gems and jewelry industry has been ranked one of the top ten export
products as shown in Table 2.1 (Information and Communication Technology Center
[ICTC], 2007).
4
Table 2.1 Export Value of Thai Industrial Goods, Year 2004 to 2007 (January - May)
Source: ICTC (2007)
Note: Value in million baht
5
The main markets for Thai jewelry export products are shown in Figures 2.1 to
Figure 2.3. The United States of America (USA) is the biggest market for both gold
and silver jewelry; Thailand is dominant in silver jewelry and the value is increasing
each year.
35,000.00
30,000.00
25,000.00
2002
20,000.00
2003
15,000.00
2004
10,000.00
2005
5,000.00
2006
0.00
USA
UK
Germany
Japan
France
Figure 2.1 The Top Five Ranking of Thai Jewelry Exports Value by Country
Source: The Gem and Jewelry Institute of Thailand (Public Organization) [GJIT]
(2007)
Note: Value in million baht
30,000.00
25,000.00
2002
20,000.00
2003
15,000.00
2004
10,000.00
2005
5,000.00
2006
0.00
USA
UK
Hong Kong
Israel
Germany
Figure 2.2 The Top Five Ranking of Thai Gold Jewelry Exports Value by Country
Source: GJIT (2007)
Note: Value in million baht
6
10,000.00
8,000.00
2002
6,000.00
2003
4,000.00
2004
2005
2,000.00
2006
0.00
USA
UK
Germany
Japan
France
Figure 2.3 The Top Five Ranking of Thai Silver Jewelry Exports Value by Country
Source: GJIT (2007)
Note: Value in million baht
Before 2005, the Thai silver jewelry held the first place in the market share in
the USA, but lost share to China in 2005, because Chinese silver jewelry is rapidly
rising at a growth rate of around 20 percent every year, whereas Thai is 12 percent
(Figure 2.4). (GJIT, 2007)
400
300
2002
2003
200
2004
100
2005
0
2006
China
Thailand
Italy
India
Mexico
Figure 2.4 The Market Share of Silver Jewelry Import into the USA Market in 2002 2006
Source: GJIT (2007)
Note: Value in million US dollars
7
Others, 17%
China, 30%
Mexico, 5%
India, 8%
Italy, 15%
Thailand,
25%
Figure 2.5 The Market Share of Jewelry Import into the USA Market in Year 2006
Source: GJIT (2007)
Nowadays Thailand has about 25 percent of the market share in the USA,
whereas the next ranking; Italy, India and Mexico, have 15, 8 and 5 percent
respectively (Figure 2.5). Export of silver jewelry from China has been growing
rapidly. Although this situation will not eliminate the existing jewelry industry in
Thailand soon, it is likely to obstruct Thai jewelry future growth.
At present, the jewelry industry is a highly competitive market, especially with
the low labor cost countries that have excess labor, like China and India. Recently,
Thai jewelry lost the GSP benefit from the USA, and needs to pay for tariff. This
means it is obviously harder to compete in terms of price. However, although the
jewelry market is very price competitive, jewelry is about fashion and there is still
room for other strategies: such as shorter time-to-market, better quality and increasing
the variety of products (GJIT, 2007).
2.2 Gems
2.2.1 The meaning and classification of gems.
Gems or Gemstones mean substances that are beautiful or durable or rare. The
level of gem beauty is dependant on its color, transparency, brilliancy, luster and fire
(or dispersion) (Keankeo, 2004; Manikhajit, 1995; Sahavat, 2006). The durability of a
gem depends on its hardness, toughness and stability (Sahavat, 2006). There are
several ways to classify gems, such as by its value (precious or semiprecious), by
origin (natural of synthetic), by treatment (enhanced or unenhanced) and so on
(Smigel, 2007). Keankeo (2004) suggested that by trade business classification, the
8
gems were classified into three groups, including: natural gems, synthetic gems, and
imitation or simulants).
2.2.2 Synthetic gems.
Synthetics are man-made gem products. Synthetics can be exact copies of
natural gems, or unique materials which are not found in nature. One type of
synthetics is the “artificial gems” which are manufactured to imitate the other gems.
For example, cubic zirconia (CZ) is a synthetic diamond simulant, the imitation copy
the look and color of the real stone but do not have the same chemical, physical and
optical properties (Gemstone, 2007; Smigel, 2007). Glass and plastic is a common
type of artificial gem, Swarovski (from Switzerland) and Preciosa (Czech Republic)
are examples of the main artificial gem brands that were commonly used by the case
study company.
2.3 Jewelry Production
Likittachai (2007) stated that jewelry can be produced by several methods, as
follows:
1) Handmade: jewelry is produced piece by piece, one piece per one design.
The
advantages
are
precision,
uniqueness,
and
durability.
The
disadvantages are slow production, high expense, and it is time consuming
and depends on worker skill.
2) Casting: jewelry is produced in massive quantities, and there could be
many pieces with one design. The advantages are fast production, less
costs if produced in big quantities and slightly dependant on workers’
skills. The disadvantages are less precise than handmade, less beautiful
than handmade and stamping, and might comprise an air bubble during
casting which could cause a hole on the surface or inside and result in
undurable jewelry.
3) Stamping: jewelry is produced in massive quantities, and there could be
many pieces with one design. Normally used for producing earrings, coins,
etc. The advantages are consistent quality, less cost and time, needs little
trimming before polishing and can be thinner than casting (leading it to be
competitive in term of price).
4) Die-struck: this method is very expensive.
9
2.4 The Case Study Company: Sterling Silver Jewelry
The selected case study company is located in Bangkok and its factory is in
Nonthaburi province. The company was found in 1999. The company developed from
a retailer to a manufacturer. At present, the company has 63 employees and is
managed by the owner’s family. The company does not have an official
organizational structure; however the draft organizational chart is shown in Figure
2.6. The company manufactures fashionable sterling silver jewelry for girls and young
women which may be decorated with synthetic gems, paint, crystal and others. The
main products are earrings and nose jewelry that is for exporting only, with revenue
earnings of about 70 million baht annually. The company has designers that create the
new jewelry styles and propose them to the main customer. The company’s main
customer is in the United Kingdom, and they have stores in many countries such as
Austria, Belgium, Canada, the USA (United States of America), Switzerland, etc. Due
to rapid expansion, the company needs to outsource using the surrounding
communities. Some outsourcers are the company’s skilled workers that became
owners of businesses; however the jobs are still performed by members in the
outsourcers’ families. Therefore the defects can be found after the products are
returned and checked by the company. Besides the defects found, the company also
faces loss in the main material, sterling silver that is given to the outsourcers, and has
extra costs incurred from mistakes in identifying the product items that are sent to the
outsourcers due to an inability to track and trace the product type and production
route. Contaminated metal, such as lead, in jewelry that the customer does not allow
in jewelry is another problem that the company faces. Moreover, the company also
wants to prevent other metal contaminations, such as with nickel occurrence, before it
happens. The major production processes of the case study company are divided into
three groups, i.e. silver tubing, silver stamping, and silver casting. The draft flow
charts are shown in Figures 2.7 to 2.9, the processes that can be outsourced are in the
bold boxes.
10
Managing
Director
Finance
Accounting
Marketing
Product
Design
Production
Sample
Preparation
Figure 2.6 The Draft Organizational Chart of the Case Study Company
Silver and copper
mixing and melting
Pressing into sheet
Rolling sheet to
form tube
Roll tube around
the axis, like a
spring.
Cut a silver spring
into hoops.
Polishing and
decorate the silver
hoop.
Attaching a wire to
the silver hoop for
holding
Final polishing
Anti-tarnish coating
Packing
Figure 2.7 Silver Tubing Process in the Case Study Company
11
Export
Silver and copper
mixing and melting
Pressing into sheet
Silver Stamping
Checking and
comparing to design.
Attaching a pin to the
stamped silver for
holding
Polishing
Decorate the stamp
silver such as coloring,
stone setting and etc.
Final polishing
Anti-tarnish coating
Packing
Figure 2.8 Silver Stamping Process in the Case Study Company
12
Model making
Rubber mold making
Wax spueing
Wax tree making
Investment
Silver casting
Cut silver casting
from silver tree to
be in piece.
Polishing
Decorate the silver
casting such as
coloring, set stone,
gold plating and
etc.
Polishing
Anti-tarnish coating
Packing
Figure 2.9 Silver Casting Process in the Case Study Company
13
The other problems that the company faces are over stock due to the company
does not have ability to determine the product statuses whether where they are, and in
which processes, so the records for production traceability could be used for tracking
the statuses of the products.
2.5 The Overview of Production Traceability
The production traceability has been used by many industries for lot tracing,
both in manufacturing and service such as food, electronics, automotive, medical, and
logistics (Ministry of Economy, Trade and Industry [METI], 2003; Töyrylä, 1999).
The majority product types that use traceability systems are human life effect
products, high value products, products that comprise several and complicated
components materials and so on. The benefits of production traceability that found in
these industries are product recall application, product liability prevention, quality and
process improvement, proof of product quality and product origin, tracing and
tracking the route of products in logistics, security application, after sales service
application, and accounting application (METI, 2003; Petroff, 1991; Töyrylä, 1999).
A production lot traceability system has significant impact on both product costs and
quality, and can have a major impact on business competitiveness. A company needs
to have an efficient lot tracing system in order to survive (Petroff, 1991).
The followings are examples of traceability systems applying in industries
(METI, 2003):
•
In food industry: processed foods; like canned food, vegetable in
packaging, is identified the manufactured or expired date. In Japan, the
consumers are allowed to access production and manufacturing
information from the internet
•
In electronics industry: to promote environmental protection, the
recycling efforts needed through registration and management of
information on component materials used in the manufacture of products.
An identification and traceability system, to recover these materials to be
recycled, is needed
•
In automotive industry: an automotive industry needs a production
traceability system to trace for product safety by documentation, and
14
manage the records of machines used for manufactures, part lot numbers
and parts that were repaired or replaced
2.6 Product Classification
A priority task in developing a production traceability system is to develop a
standard product coding and classification system for identifying products (METI,
2003). The product coding and classification system can be designed by several
ways, the examples are as follows:
•
Hospital: a coding system is defined by classifying to be many groups
such as disease coding groups, drug coding groups, hospital coding
groups, personnel position coding groups and so on. Each classification
groups have different design structures of coding systems that appropriate
to the purpose use. For example, the diseases coding groups follow the
International Classification of Diseases: ICD) that use three to five digits
of alphanumeric, the personnel position coding groups use the two digits
defined by each hospital (Department of Industrial Engineering [DIE],
2006.)
•
Publishing: the international standard likes ISSN (International Standard
Serial Number) and ISBN (International Standard Book Number) are
widely used
2.7 Product Classification of Jewelry
Hendry (2004) has invented the system and method for appraising and
describing jewelry and other valuable items such as antiques, gemstones, fine China
antiques and other collectibles. The objectives of inventing this system and method
are for making appraisals, detailed descriptions, insurance underwriting assessment,
claims adjustment, and the like. The invention provided examples of the system by
using data processing system that guiding a user through series of forms on the
computer screen to fill in or drop down list menus to choose. The data sets of various
classes of the valuable items were kept in database. The items are classified by
descriptions that built of sets of elements that users will choose associate elements to
build the description. For the jewelry classification, the examples of classes are ring,
bracelet, necklace, or other jewelry items, and examples of elements are:
15
•
type, size, weight, color, cut, and clarity of a gemstone
•
material, styling, and style of setting or mounting the gemstone on such
jewelry
The detailed examples of the above classification of jewelry are listed in Table 2.2.
Table 2.2 Examples of Design Classification for Jewelry
Classification Level
Primary Level
Loose Goods
Second Level
Third Level
Fourth Level
Diamonds
Assorted Cuts
Round
Assorted Sizes
.01 - .12 cts
.13 - .24 cts
.25 - .49 cts
.50 - .74 cts
.75 - .994 cts
.995 - 1.49 cts
1.50 - 1.99 cts
2.00 - 3.00 cts
3.01 cts up
Marquise Cut
Emerald Cut
Pear Cut
Oval Cut
Tapered Baguette
Baguette Cut
Fancy Cut
Precious Gems
Emerald
Ruby
Sapphire
Gems Stones
Alexandrite
Almandite Garnet
Amber
Amethyst
Andalusite
Aquamarine
Beryl
Bloodstone
Chrysoberyl
Citrine
Coral
Cubic Zirconium
Demantoid Garnet
Fire Agate
Garnet
Garnet-Almandite
Garnet- Demantoid
16
Garnet- Grossularite
Garnet- Pyrope
Garnet-Rhodolite
Garnet- Spessartile
Garnet-Tsavorite
Grossularite Garnet
Hematite
Iotite
Jade - Jadeite
Jade - Nephrite
Jet
Kunzite
Lapis Lazuli
Malachite
Moonstone
Morganite
Mother of Pearl
Onyx
Opal
Opal - Black
Opal - Boulder
Pearl
Peridot
Pyrope Garnet
Quartz
Rhodolite Garnet
Rubellite
Sardonyx
Shell
Spessartite Garnet
Spinel
Tanzanite
Tiger - Eye
Topaz
Tourmaline
Tsavorite Garnet
Turquoise
Zircon
.01 - .49 cts
.50 - .99 cts
1.00 - 1.49 cts
1.50 - 1.99 cts
2.00 - 2.99 cts
3.00 - 3.99 cts
4.00 - 4.99 cts
5.00 - 7.99 cts
8.00 - 11.99 cts
12.00 - 14.99 cts
15.00 - 19.99 cts
20.00 - 24.99 cts
25.00 cts up
Other
Other Stones
Strung Pearls
Mixed Millimeter
Assorted Shapes
Round
Off Round
17
Oval
Pear/ Tear Drop
Rice
Baroque
Other Shapes
0 - 2 Millimeter
3 - 4 Millimeter
5 - 6 Millimeter
7 - 8 Millimeter
9 - 10 Millimeter
11 - 14 Millimeter
15 Millimeter up
Mounted Diamond
Platinum Diamond
Jewelry
Lady’s Ring
Anniversary
Ballerina
Band
Cameo
Class
Coin
Engagement
Fancy
Fraternal
Insert
Intaglio
Ring Jacket
Signet
Waterfall
Wedding
Wedding Set
Wrap
Other
Men’s Ring
Anniversary
Band
Cameo
Class
Coin
Fancy
Fraternal
Intaglio
Signet
Wedding
Other
Lady’s Jewelry
Barrette
Bracelet
Bracelet - Bangle
Bracelet - Cameo
Bracelet - Coin
Bracelet - Cuff
Bracelet - Intaglio
Bracelet - Jacket
Bracelet - Tennis
Brooch
Button Covers
18
Case
Charm
Clasp
Clip
Compact
Earrings
Earrings - Cameo
Earrings - Coin
Earrings - Cuff
Earrings - Foldover
Earrings - Intaglio
Earrings - Jacket
Earrings - Studs
Enhancer
Jabot
Locket
Necklace
Pendant
Pendant - Cameo
Pendant - Coin
Pendant - Intaglio
Religious
Studs
Tie Chain
Watch Attachment
Watch Bracelet
Watch Strap
Other
Men’s Jewelry
Belt Buckle
Bracelet
Bracelet - Cameo
Bracelet - Cuff
Bracelet - Intaglio
Button Covers
Case
Clip
Cuff Links
Earrings
Earrings - Cameo
Earrings - Coin
Earrings - Cuff
Earrings - Foldover
Earrings - Intaglio
Earrings - Jacket
Earrings - Studs
Necklace
Pendant
Pendant - Cameo
Pendant - Coin
Pendant - Intaglio
Religious
Stays
Studs
Tie Bar
Tie Chain
Tie Tack
Watch Attachment
19
Watch Bracelet
Watch Strap
Other
Karat Yellow Gold
Diamond Jewelry
Lady’s Ring
Men’s Ring
Lady’s Diamond &
Colored Stone Ring
Men’s Diamond &
Colored Stone Ring
Lady’s Jewelry
Men’s Jewelry
Karat White Gold
Diamond Jewelry
Lady’s Ring
Men’s Ring
Lady’s Diamond &
Colored Stone Ring
Men’s Diamond &
Colored Stone Ring
Lady’s Jewelry
Men’s Jewelry
Karat Gold Diamond
Jewelry
(Other than YG or
WG)
Mounted Precious
Gems
(Emerald, Ruby,
Sapphire)
Platinum Precious
Gem Jewelry
Lady’s Ring
Men’s Ring
Lady’s Jewelry
Men’s Jewelry
Karat Yellow Gold
Precious Gem Jewelry
Karat White Gold
Precious Gem Jewelry
Karat Gold Precious
Gem Jewelry
Mounted Gems
(other than
Diamond, Emerald,
Ruby, Sapphire)
Platinum Gem Jewelry
Lady’s Ring
Men’s Ring
Lady’s Jewelry
Men’s Jewelry
Karat Yellow Gold
Gem Jewelry
Karat White Gold
Gem Jewelry
Karat Gold Gem
Jewelry
Platinum and Karat
20
Gold Jewelry
Platinum Jewelry
Lady’s Ring
Men’s Ring
Lady’s Jewelry
Men’s Jewelry
Karat Gold Jewelry
Lady’s Ring
Men’s Ring
Baby Ring
Chain
Lady’s Jewelry
Men’s Jewelry
Silver Jewelry
Lady’s Ring
Men’s Ring
Chain
Lady’s Jewelry
Men’s Jewelry
Gold Plated, Filled
and Other Jewelry
Lady’s Ring
Men’s Ring
Chain
Lady’s Jewelry
Men’s Jewelry
Watches
Watches with Stones
and Karat Gold or
Platinum
Lady’s Platinum &
Stone Watch
Men’s Platinum &
Stone Watch
Lady’s Karat Gold &
Stone Watch
Men’s Karat Gold &
Stone Watch
Watches - Karat Gold
or Platinum
Lady’s Platinum
Watch
Men’s Platinum
Watch
Lady’s Karat Gold
Watch
Men’s Karat Gold
Watch
Dress
Pocket
Sport
Other
Lady’s Watch
Dress
Pocket
Sport
Other
Men’s Watch
21
Dress
Pocket
Sport
Other
Source: Hendry (2004)
This design classification that revealed by Hendry (2004) covered a wide
range of types of jewelry. The classification system was invented for the purpose of
assessing the value of such items such as making appraisals, detailed descriptions,
insurance underwriting assessment, claims adjustment, and so on. In this thesis,
however the focus will be on the fashionable sterling silver jewelry in the case study
company, for the traceability purposes. Hendry’s classification is used only as a
guideline and many adaptations may be needed.
2.8 Method for Developing the Product Classification and Coding System
Group technology (GT) is an engineering and manufacturing methodology
used for improving productivity by grouping parts and products based on their similar
characteristics (geometry or manufacturing process) into families.
GT begins by grouping part families based on their attributes. There are three
methods to form part families: manual visual inspection, production flow analysis,
and classification and coding (Anlağan, 1996). In this thesis, the classification and
coding method has been focused on and used.
A manufacturing system can be separated into smaller subsystems of part
families based on similarities in design attributes and manufacturing attributes.
Examples are as follows (Britton, 2000; Hyer & Wemmerlöv, 1984):
•
Design attributes: part configurations (such as round, square), dimension
envelops (such as length to diameter ratio), surface integrities (such as
surface roughness, dimensional tolerances), material types, raw material
stages (such as casting, forging, bar stock) and so on
•
Manufacturing attributes: operations and operation sequences (turning,
milling, etc.), batch sizes, machine tools, cutting tools, work holding
devices, processing time, etc
Examples of design and manufacturing attributes that are typically included in
a group technology classification and coding system are shown in Table 2.3.
22
Table 2.3 Examples of Design and Manufacturing Attributes included in a
Classification and Coding System
Design Attributes
Manufacturing Attributes
Basic external shape
Major processes
Basic internal shape
Minor operations
Rotational or rectangular shape
Operation sequence
Length-to-diameter ratio (rotational parts)
Surface finish
Aspect ratio (rectangular parts)
Machine tool
Material type
Production cycle time
Part function
Batch size
Major dimensions
Annual production
Minor dimensions
Fixtures required
Tolerances
Cutting tools
Source: Britton (2000) and Hyer and Wemmerlöv (1984)
The GT classification and coding method is achieved by classifying parts
according their design and manufacturing attributes. The GT classification method
usually classifies a structuring of part or product attributes into a set of families that
have similar attributes. However the attributes may be in the wide variety of
characteristics, such as geometrics, material ingredients, function and so on, a careful
definition of attributes needs to be considered. For example, parts that are similar in
one set of attributes (such as shape, sizes) may not similar in the other attributes (such
as color, weight). This is a fact that there is no single way to classify parts or products.
Each part and product classification system needs to be developed bases on the
intended use. However, families should cover all parts or products and also each part
or product should be able to assign only one family (Britton, 2000; Hokey & Shin,
1994).
Examples of reasons to use a coding system are as follows:
•
Design information retrieval and variety reduction: during part
developing task, a designer can determine if a similar part has already
existed. A simple change in an existing part would take much less time
than designing a whole new part.
23
•
Improving manufacturing performance: a part code for a new part can be
used to search for process plans for existing parts with similar codes.
To assign symbols in the GT coding system is based on three different
structures of codes as follows (Anlağan, 1996; Min & Shin, 1994):
•
Monocode or hierarchical structure
•
Polycode or attribute structure or chain code
•
Mixed code or hybrid structure
2.8.1 Monocode or hierarchical structure.
This coding system was originally developed for biological classification in
18th century. The monocode structure is like a tree in which each digit(s) amplifies the
information provided in the previous digit(s). The first digit represents an entire group
and the next digit(s) represents sub-groups and so on. The meaning of each digit(s) is
dependant on the previous digit(s) in the code. An example is shown in Figure 2.10.
The advantages of monocode are as follows:
•
with a relatively small numbers of digits, a large amount of information
can be stored
•
it is useful for storage and retrieval of the design-related information such
as the part geometry, material, size, etc
The disadvantages of monocode are as follows:
•
it is difficult to define the meaning for each digit
•
in the different sub-groups may have different levels of sub-sub-groups,
therefore the codes in some positions may be blank
24
Figure 2.10 Example of Monocode (Hierarchical Structure)
Source: Joneja (2003)
2.8.2 Polycode or attribute structure or chain code.
The code symbols are independent of each other. They are fixed position
codes. Each digit(s) in a specific location of the code describes a unique property of
the feature, thus the value of any given digits within the code has no relation to the
other digits.
The advantages of polycode are as follows:
•
it is easy to formulate
•
it is easy to understand and is useful in manufacturing situations where
manufacturing processes have to be described
The disadvantages of polycode are as follows:
•
length of codes may become excessive and very long because less
information can be stored per digit
•
to compare the coded parts, such as to check for similarity, requires more
works because needs to compare every digit and each digit is not related to
the others
2.8.3 Mixed code or hybrid structure.
It is the mixture of both monocode (hierarchical structure) and polycode
(attribute structure) systems by using the monocode when can and use the polycode
for the other digits. The model structure of the mixed code is shown in Figure 2.11.
The mixed code retains the advantages of both systems; it is the most commonly used
25
the structure of coding and classification. A code created by using mixed code
structure would be relatively more compact than a pure attribute code (polycode)
structure while retaining the ability to easily identify parts with specific
characteristics.
Figure 2.11 Model Structure of Mixed Code (Hybrid Structure)
Source: Joneja (2003)
One example of the mixed code structure that is widely used by industries and
provides a basic framework for understanding the classification and coding process is
the Opitz coding system. The Opitz coding system was developed by Dr. H. Opitz,
Technical University of Aachen in 1970. It considers both design and manufacturing
information. The basic structure of the Opitz coding system comprises of three groups
of digits as shown in Figure 2.12. The example of form code (digits 1 to 5) for the
rotational parts in the Opitz coding system is shown in Figure 2.13.
26
Form code
Supplementary code
Secondary code
12345
6789
ABCD
Part geometry and features
Information relevant to
Production processes and
relevant to part design
manufacturing (polycode)
production sequences
Figure 2.12 The Basic Structure of Opitz Coding System
Source: Anlağan (1996) and Özdemir (2005)
27
Figure 2.13 Form Code (Digits 1 to 5) for Rotational Parts in the Opitz Coding System
Source: Özdemir (2005)
1
28
Although the Opitz coding system is a widely used system but Fatheldin and
Kirkpatrick (1968) had mentioned as follows:
Opitz system is suitable both for design retrieval as well as for the formation
of parts families for cellular manufacture. This point is disputed by other
researchers. Some criticisms of Opitz’s code are:
1) Washers which are identical from the design point of view can be
produced by (i) sawing off from a tube, (ii) turning from a bar, and (iii)
stamping from a strip.
2) The choice of the L/D ratio for the first code digit brings components of,
say, L = 100, D = 20 together with those of L = 1,000, D = 200. The two
types of components have different production requirements.
3) The code does not distinguish between the internal and external teeth for
gears, the number of teeth, and so on.
... It indicates that, whilst universal codes may be useful as the first step in
adopting a code, it is usually necessary to modifications to better
accommodate the requirements of the particular firm. (as cited in Lee, 1984,
p. 5)
Anlağan (1996) suggested about an important to understand the attributes of
classification and coding system for the purpose of selecting or developing coding
system that met company needs. Some of the important classification and coding
system attributes that should be considered were as follows:
1) Flexibility for various applications such as part family formation, process
planning, costing, and purchasing
2) Accuracy, to provide correct information on parts
3) Expandability, to utilize information on more part attributes
4) Ease of learning
5) Ease of retrieval
6) Reliability and availability of software
7) Suitability for specific applications
29
Hyer and Wemmerlöv (1989) mentioned that the process to perform coding
and classification could be completely manual or computer-assisted with interactive
expert-system (as cited in Tatikonda & Wemmerlöv, 1992).
2.9 Method for Developing the Production Traceability System
Considering that the information that is relevant to the production traceability
are still vague and undefined, the historic information regarding the actual production
records such as the production history and the transaction history should be treated
carefully (METI, 2003).
Steele (1995) defined the data contents required to collect for a production
traceability system, the following information was considered necessary:
1) The processes or component materials used to make this product and the
characteristics of these processes or component materials.
2) The process records, component material sources, letter of analysis, or
certificates that show the level of compliance to the specification.
3) The other items that may be defective. If the processes or component
materials are suspected to be defective, those items may need to be
inspected or repaired.
The needed information is dependant on the purposes of the production
traceability, the company, and the industry, and can be considered in the following
perspectives: the frequency of the referring information (real time or on demand
information), the amount of the information used (complete product life cycle process
from production, only production records or only information required by customer)
and the details of the information required for traceability (each item, need
serialization, each lot or only product code or type) (METI, 2003; Steele, 1995).
Steele (1995) suggested that to design a production traceability system,
required the unique identification for a physical lot, data recoding for lot movement,
lot-process linking to the process data, and reporting that retrieves the lot-tracing data
from the system to find source lots or component materials associated with a
suspected lot.
30
Chapter 3
Research Methodology
3.1 Introduction
The purpose of this study is to develop the product classification and
production traceability system for the sterling silver jewelry company. The literatures
were examined by focusing on the product classification and coding, and the
production traceability. The related literature was reviewed to synthesize ideas to
develop the product classification and production traceability system used in this
research. This chapter describes the methodology that is used in the research, which
included data collection, system development, field-test and system adjustment as
shown in Figure 3.1.
Data
Collection
System
Development
Literature
Review
System
Adjustment
Field-Test
Figure 3 The Methodology used in this Thesis
3.2 Data Collection for Studying Products and Processes in the Case Study
Company
To ensure the reliability of the data findings for developing the system in this
case study company, several data sources were collected. The data collection in this
study used multiple sources of evidences, which adapted from Yin (2003), including
documentation, interviews, direct observations and physical artifacts. Yin (2003)
suggested that no single source has a complete advantage over all the others. In fact,
the various sources are highly complementary, and a good case study will therefore
want to use as many sources as possible.
31
3.2.1 Documentation.
Yin (2003) suggested that documentary information was useful, but it could
have bias and must carefully use. For a case study, the document should use as an
additional evidence from the other sources. The case study company is a family
business that has only a few documents in its system; the collected documentary
information was described in Chapter 4.
3.2.2 Interviews.
Rubin and Rubin suggested that the interview was one of the most important
sources of a case study information and appeared to be a guide conversation rather
than structured questions; it was likely to be fluid rather than rigid (as cited in Yin,
2003). It was able to provide shortcuts to the prior history of the situation and identify
the other relevant sources of evidences (Yin, 2003). In this thesis, the several
interviews were conducted to get the details and update data, checked the company
requirements, and discussed the result of the field test.
3.2.3 Direct observations.
Yin (2003) suggested that the direct observations could range from formal to
causal data collection activities, and the field-workers might be asked during
observation. The direct observation might be made throughout the field visits,
including during which other evidences, such as from the interviews. The
observational evidences were useful in providing additional information about the
topic being studied. In this thesis, many direct observations were performed, almost
every visiting during the development of the system.
3.2.4 Physical artifacts.
Yin (2003) suggested that physical artifacts have less potential relevance in the
most typical kind of case study. However, when relevant, the artifacts can be an
important component in the overall case. The examples of the physical artifacts are a
technological device, a tool, a work of art, and so on. Therefore, the case study
company’s products, parts, material and tools were investigated.
32
3.3 System Development
To develop the system of the jewelry design information retrieval and the
production traceability based on interviews and workshops with the case study
company’s executive, designers, and operators, as well as used the existing database
and the information retrieval systems. The developed system had the unique
identification for product lot, data collection for tracing the lot movement.
3.4 Field-Test
The field-test of the developed prototype to ensure the operational
acceptability and practically by implementing the product classification and the
production traceability system in the company and interviewed the associated people
such as the company executive, designers, and operators for practical use and gather
information for revision the developed system.
3.5 System Adjustment
The developed system was adjusted according to the information receiving
until the system was considered satisfactory by the company executive through the
questionnaire.
33
Chapter 4
Development and Application of the System
This chapter presents the development, application and result of the product
classification and production traceability system in the case study company which
included: the data that are collected from each source, the development of the product
classification and coding, and the development of the production traceability system.
4.1 The Collected Data
According to the data collection to study products and processes in the case
study company that described in Chapter 3. The data were collected by using four
sources of evidences: documentation, interviews, direct observations and physical
artifacts. The results were as follows:
4.1.1 Documentation.
The case study company is a family business that had a few documents in its
system. The main documentation and information related in this thesis were
summarized in Table 4.1.
Table 4.1 The Case Study’s Documentary Information
Document
Information Related to This Study
Remark
Title
Customer
− Customer product code
Purchase
− Product description
Order (PO)
− Product picture (hand-written form)
− Product quantity
− Ornament type and color (such as pink
rhinestone, white cubic zirconia)
− Type of finished card (for packing)
− Process group (i.e. tubing, stamping and
casting)
− Delivery date
Delivery Bill
− Product description
The company uses
− Product picture (hand-written form)
this document for
− Product quantity, total weight
making order to
34
− Ornament type and color (such as pink
outsourcers.
rhinestone, white cubic zirconia)
− Material or part weights sent to and returned
from outsourcers
− Outsourcer’s name
− Order date
− Task ordering (such as stamping, attaching
holding pins)
Task
− PO number
The company uses
Ordering
− Product description
this document after
Form (use
− Product picture (hand-written form)
this thesis was started.
both internal
− Product quantity, total weight
and
− Ornament type and color (such as pink
outsourcers)
rhinestone, white cubic zirconia)
− Material or parts weight sent to and return
from outsourcers
− Outsourcer’s name or operator name
− Order date
− Task ordering (such as packing, ornament
setting)
Company
− Company’s products
Draft version and
Profile
− Annual revenue
unofficial
− Number of employees
− Location
Polishing and
− Polishing or anti-tarnish date
Anti-tarnish
− Product picture (hand-written form)
Record (in
− Part or product weight (before and after this
book form)
process)
− Operator name
4.1.2 Interviews.
In this thesis, the gemology experts, the company management and
employees, and the outsourcers were interviewed. The interviews allowed them to
express their thoughts in their own words, which were useful to find out information
that could not be observed. The interview guidance was developed in semi-structured
questions and open-end questions as shown in Appendices A and B.
35
Two gemology experts- an Assistant Professor and an instructor who teach in
the faculty of science in a Thai university and who conduct jewelry and gemology
courses for trainees in the gem and jewelry industry- were interviewed about the
international or standard coding and classification for gems and jewelry. The coding
and classification of jewelry that used by commercial is coded by each organization.
At present, they did not see any international or standard coding system for jewelry.
For gems, the system used by gemologists to classify gems includes: groups, species
and varieties. The “groups” are two or more chemically related gem species that have
similar properties and structures such as the garnet group, feldspar group, and so on.
The “species” is defined by the chemical composition and crystalline structure such as
pyrope, almandine, spessartine, etc. The “varieties” is subdivided from the “species”;
the classifications can be based on color, color distribution, transparency, optical
phenomena, other especial appearance or any combination such as ruby, sapphire, etc.
However, this classification is used for the natural gems classification, while the case
study company in the scope of this study uses the synthetic gems, which might not
appropriate to use by the case study company, but could be used as a guideline.
The company management and employees were interviewed about the product
details (such as material, type, color, supplier codes, customer coding), the process
details (such as the process routes and linking) and the systems (such as the available
product classification and coding, and the production traceability system).
4.1.3 Direct observations.
In this thesis, direct observations of the internal and some outsourcers’
production processes were made, both intentionally and during the collection of other
evidences such as interviews, and document reviews. The observational data were
collected during the field visiting and meeting.
4.1.4 Physical artifacts.
The examined physical artifacts were the company’s products (including parts
and materials). The products were examined for their attribute details of classification
and coding.
The collected data were examined, analyzed and organized according to the
case study company’s processes. The details are as follows: the production process of
36
the company is divided into three groups, which are the silver tubing, the silver
stamping, and the silver casting. The main production process flows that commons for
these three process groups is shown in Figures 4.1 and 4.2, and the details of three
process groups are in Figures 4.3 to 4.5, the process steps that can be outsourced are
shown in each process flows in dash and double line style boxes. The support process,
pin making, is shown in Figure 4.6.
37
Product design
Internal
Outsource
PO receiving
Internal or Outsource
Job assignment
Tubing
Tubing, Stamping, or Casting?
Casting
Stamping
Tubing process
Stamping process
Weighing
Polishing
No
Antique-treatment process?
Yes
Antique-treatment process
Cleaning exceeding antiquetreatment by polishing
Weighing
Job Assignment
A
38
Casting process
A
No
Coloring process?
Yes
Coloring process
No
Stone setting process?
Yes
Job Assignment
Stone setting process
Quantity counting and
recording
Final polishing
Anti-tarnish coating
Product weighing
Jewelry stock keeping, and
waiting for packing
Purchasing order preparing
Pack to Card
Counting and preparing for
export
Figure 4.1 Main Process Flow in the Case Study Company
39
Silver and copper mixing
Internal
Outsource
Silver and copper melting
Internal or Outsource
Forming into string
Pressing into sheet
Rolling sheet to form tube
Rolling tube around the axis,
like a spring
Cut a silver spring into hoops
Pin Making Process
Attaching a holding pin
Figure 4.2 Silver Tubing Process Flow in the Case Study Company
Silver and copper mixing
Internal
Outsource
Silver and copper melting
Internal or Outsource
Pressing into sheet
Silver stamping
Checking compare to design
Pin Making Process
Attaching a holding pin
Figure 4.3 Silver Stamping Process Flow in the Case Study Company
40
New mold-design
Already have mold
New model making
Rubber mold making
Rubber mold Requesting
Wax spueing
Wax tree making
Making lime mold from wax
tree
(Investing)
Internal
Outsource
Internal or Outsource
Mixing and melting silver and
copper into lime mold
Silver tree casting
Cleaning silver tree by dipping
into acid
Weigh the total silver tree
Cut silver branches from silver
core
Calculate the total silver
weigh; branches and core
Cleaning silver branches by
polishing
Cut silver pieces from branches
Polishing
Pin Making Process
Attaching a holding pin
Figure 4.4 Silver Casting Process Flow in the Case Study Company
41
Silver and copper mixing
Internal
Outsource
Silver and copper melting
Internal or Outsource
Silver bar casting
Forming into wire
Keep into stock
Request silver wire from stock
Feed into pin making machine
Weighting and packing
Keep into stock
Making pin for nose jewelry
Figure 4.5 Silver Pin Making Process Flow in the Case Study Company
4.2 Development of Product Classification and Coding
4.2.1 Development of product families.
From the product details gathering from the data collection, the products and
their parts (or materials) were grouped and classified into families. The higher levels
of the families are composed of the lower levels. For example, the highest level of the
families is the “finished goods” which means the jewelry being attached (packed) to
the finished card. The “jewelry” family means the semi-jewelry (jewelry body) that
has already been attached the accessories (such as holding pin for earrings) and
decorated with the ornaments. The structure of the product families is shown in Figure
4.7.
42
Material (G)
Label and
Sticker
(L)
Silver Solder
Silver granule
925
sterling
silver
Copper granule
Semi-jewelry (D)
Accessories (E)
Accessory Material
Jewelry
(B)
(Silver pin, Fish wire, wire,
silver ball, etc.)
Ornaments (F)
Finished
goods
(A)
(Gems, Rhinestone, Acrylic,
Paint, Pearl, etc.)
Card
(C)
Packing
Material
(P)
Foam (black, white)
Plain card
Finished
card
Packaging (Carton, Plastic bag, etc.)
Figure 4.6 The Structure of Product Families
4.2.2 General coding structure.
All coding structures are applied from the mixed code (or hybrid structure) in
the group technology classification and coding system theory that explained in the
Chapter 2. The developed coding structures are composed of the alphanumeric which
has the maximum fifteen digits, the first digit is represented the product family, the
meaning of the other digits and the number of digits are dependant on each family.
Because one purpose of this development is tried to be easy to use, the number of
digits are minimize as short as possible. Therefore, each family has the different
number of digits and the different position of hyphen (“-”) signs to be used. The
developed general coding structure is shown in Figure 4.8.
(Digit) 1 - 2
(Family)
-
3
4
5
6
7
8
9
10
11
12
13
The meaning and number of digits depend on family.
Figure 4.7 The Developed General Coding Structure
43
14
15
4.2.3 Finished goods coding structure: family “A”.
The finished goods coding structure is composed of ten digits as shown in
Figure 4.9. The meaning of each digit of family “A” can be explained as follows:
•
Digit 1: this digit must be “A” only
•
Digit 2: this digit represents the number of jewelry on one finished card.
This digit uses the alphabet A to Z. For example, the A means one
finished card is attached with one piece of jewelry, B means two pieces
and so on
•
Digits 3 to 5: these digits represent the customer codes
•
Digits 6 to 10: these digits are for the unique identification for each
finished goods that the digits 2 to 5 are the same number (means the same
pieces of jewelry and the same customer)
Table 4.2 Example of Finished Goods Code: “A-B001-00001”
Meaning
Code in
Description for Code
Remark
Example
Family
A
Finished Goods
Number of Jewelry on
B
two pieces
one Finished Card
Customer Code
001
“001” code is represented the
customer named “Silver
Jewelry co., ltd.”
Unique Identification
One of finished goods that
The finished goods
for each Finished
has two pieces of jewelry on
that sold to Silver
Goods
one card and sold to Silver
Jewelry co., ltd. can
Jewelry co., ltd.
have many styles
00001
that have two pieces
of jewelry packed in
one card.
Note: In the reason of company confidential, the customer and supplier names of the
case study company in this thesis are not provided the real names
44
-
A
(Digit)
-
1
2
A
Number of Jewelry on one
Finished Card
3
4
5
6
A:1 piece
B:2 pieces
C:3 pieces
D:4 pieces
E:5 pieces
F:6 pieces
G:7 pieces
001:
002:
003:
004:
005:
006:
8
9
10
Unique Identification for
Customer
-
7
Each Finished Goods
00001,00002,...,99999.
Use for identify while the first 5
digits have the same codes.
H:8 pieces
I:
Figure 4.8 Developed Finished Goods Coding Structure (Translated from Thai)
4.2.4 Jewelry coding structure: family “B”.
The jewelry coding structure is composed of fifteen digits as shown in Figure
4.10. The meaning of each digit of family “B” can be explained as follows:
•
Digit 1: this digit must be “B” only
•
Digit 2: this digit represents the jewelry types such as earrings, nose
jewelry, necklace, and so on. This digit uses the alphabet A to Z. For
example, the B means earrings and C means nose jewelry
•
Digit 3: this digit represents the jewelry subtypes, this is monocode (or
hierarchical structure which each digit amplifies the information provided
in the previous digit), the digit 3 amplifies the information provided in the
digit 2. For example, if digit 2 is earrings which subtypes are included
stud, dangle, hoop and so on, the alphabet in digit 3 is means these
subtypes of earrings
•
Digits 4 to 7: these digits represent the design style of the semi-jewelry
used to make this jewelry, the coding structure of these digits was explain
in the semi-jewelry coding structure (digits 4 to 7 of family “D”)
•
Digit 8: this digit represents the main material uses for making the semijewelry (jewelry body) and this digit meaning is the same as main material
digit of semi-jewelry coding structure (digit 3 of family “D”)
•
Digit 9: this digit represents the surface decoration of the jewelry, such as
the “A” means gold plated, “B” means copper plated, and so on
45
•
Digits 10 to 15: these digits represent the main ornament to be decorated
in the jewelry, the coding structure of these digits was explained in the
ornament coding structure (digits 2 to7 of family “F”)
Table 4.3 Example of Jewelry Code: “B-BA-Z001-BO-CA1COO”
Meaning
Code in
Description for Code
Remark
Example
Family
B
Jewelry
Jewelry Type
B
Earrings
Jewelry Subtype
A
Stud
Others (which cannot
Design Style
Z001
classify in the other design
One of the design style
groups):- such as Geometric,
that defined in the “Z”
Chandelier, Mesh style,
design group.
Cake, Crown, Dice
Main Material of
Semi-Jewelry
B
925 Sterling silver
Surface Decoration
O
No decoration
Main Ornament to be
Used.
See the code structure of
C:CZ,
CA1COO
A1:White,
COO: round, diameter 3 mm.
46
family F: "Ornaments"
B
(Digit)
-
2
3
Jewelry
Type
Jewelry
Subtype
1
B
-
A: B:Earrings
4
-
5
6
Design Style
Design group
Unique Number
O:
A:Stud
B:UV Stud
C:Dangle
D:Hoop-Endless
E:Hoop-Snaptop
F:Hoop-Snaptop
and Endless
-
7
See the code structure of
family D: semi-jewelry
-
8
9
Main Material of SemiJewelry
A:Silver(Ag)
B:925 Sterling silver
C:Gold(Au)
D:
E:
Surface Decoration
A:Gold plated
B:Copper plated
C:Sand brush-Gold plated
D:Sand brush-Copper plated
E:
F:
G:
F:
G:
H:
H:
-
C:Nose jewelry A:Nose stud
I:
I:
B:Nose spin
J:
J:
C:Bend to fit
D:Necklace
A:15"
B:16"
C:18"
D:20"
E:Bracelet
A:6"
F:Pendant
O:ไมระบุ
G:Ring
A:Size 4
B:Size 5
C:Size 6
D:Size 7
E:Size 8
F:Size 9
H:Toe ring
A:Size 4.5+Split end
I: Anklet
A:9"
B:9"+2"
K:
K:
L:
M:
N:
O:
P:
Q:
R:
S:
T:
U:
V:
W:
X:
Y:
Z:
L:
M:
N:
O:No decoration
P:
Q:
R:
S:
T:
U:
V:
W:
X:
Y:
Z:
Figure 4.9 Developed Jewelry Coding Structure (Translated from Thai)
47
10
Material
11
12
13
14
Main Ornament to be Used.
Color
Size
See the code structure of family
F: "Ornaments"
15
4.2.5 Card coding structure: family “C”.
The card coding structure is composed of ten digits as shown in Figure 4.11.
The meaning of each digit of family “C” can be explained as follows:
•
Digit 1: this digit must be “C” only
•
Digit 2: this digit represents the card types that being used by the case
study company. The available card types are the general blue, general
violet, blue for nose jewelry, and black for nose jewelry which represented
by the code A to D respectively. In the future, the case study company can
specify more codes if there are more card types
•
Digit 3: this digit represents the adding materials stick to a card. This digit
used the alphabet A to Z, and O was reserved for without the adding
materials
•
Digit 4: this digit represents the silk screening on a card. This digit uses
the alphabet A to Z, and O was reserved for without silk screening
•
Digit 5: this digit represents the holes and wings design on the card, wings
design is used for earrings. The digit 5 is represented the number of holes
or wings on the card
•
Digits 6 to 7: the digits 6 to 7 are the unique identification numbers for
each card that the digits 2 to 5 are the same numbers
•
Digits 8 to 10: these digits represent the supplier codes
48
Table 4.4 Example of Card: “C-BOOB01-010”
Meaning
Code in
Description for Code
Remark
Example
Family
C
Card
Card Type
B
Violet card (for general)
Adding Material
O
Without adding any materials to
this card
Silk Screening
O
Without silk screening
Number of Holes or
B
Has 2 wings
01
This unique number is for
The violet card with 2 wings
identify while the first 5 digits
can have the different style,
have the same codes.
e.g. different position of
Wings
Unique Number
wings.
Supplier
010
The “010” code is represented
supplier named “Jewelry Pack
co., ltd.”.
49
C
(Digit)
-
-
1
C
-
2
3
4
5
Card Type
Adding
Material
Silk Screening
Number of Holes or Wings
A: Blue (for general)
B: Violet (for general)
C: Blue for nose jewelry
D: Black for nose jewelry
E:
F:
A: Black Foam
B: White Foam
C: Acrylic or PVC
D:
E:
F:
6
7
8
9
10
Supplier
A:"cubic zirconia"
B:"gold plate"
C:Specify price
D:"nose studs"
E:"bend to fit"
F:"nose spin"
A: 1 wing
B: 2 wings
C: 3 wings
D: 4 wings
E: 2 holes (high space between holes)
F: 2 holes (adjacent)
G:
G:
G:"cubic zirconia"+specify price
G: 4 holes
H:
H:
H:"spin fit"
H: 6 holes
I:
I:
I:"pendant necklace"
I: 2 holes (normal space)
J:
J:
J:"UV"
J: 1 hole
K:
K:
K:"piercing pour nez"
K: 3 hole
L:
L:
L:
L: 5 holes
M:
N:
O:
P:
Q:
R:
S:
T:
U:
V:
W:
X:
Y:
Z:
M:
N:
O: Without adding
P:
Q:
R:
S:
T:
U:
V:
W:
X:
Y:
Z:
M:
N:
O: Without screen
P:
Q:
R:
S:
T:
U:
V:
W:
X:
Y:
Z:
M:
N:
O: Without holes and wings
P:
Q:
R:
S:
T:
U:
V:
W:
X:
Y:
Z:
Figure 4.10 Developed Card Coding Structure (Translated from Thai)
50
Unique Number
01,02,03,...,99.
Use for identify
while the first 5
digits have the
same codes.
001:
002:
003:
004:
005:
006:
4.2.6 Semi-jewelry coding structure: family “D”.
The semi-jewelry coding structure is composed of seven digits as shown in
Figure 4.12. The meaning of each digit of family “D” can be explained as follows:
•
Digit 1: this digit must be “D” only
•
Digit 2: this digit represents the major process for making semi-jewelry
(jewelry body.) There are included: stamping, casting, and tubing which
represent by A, B, and C respectively
•
Digit 3: this digit represents the main material uses for making semijewelry (jewelry body.) There are included: silver (Ag), 925 sterling
silver, and gold (Au), which represent by A, B, and C respectively
•
Digits 4 to 7: these digits represent the design style of the semi-jewelry,
the digit 4 is represented the design group such as animal, plant, star, heart
and so on. The digits 5 to 7 are unique identification numbers for each
design group, due to one design group can have many design styles
Table 4.5 Example of Semi-Jewelry: “D-AB-Z001”
Meaning
Code in
Description for Code
Remark
Example
Family
D
Semi-Jewelry
Process
A
This semi-jewelry is
produced by stamping
process.
Main Material
Design Style
B
Z001
925 Sterling silver
Others (which cannot
One of the design style
classify in the other design
that defined in the “Z”
groups):- e.g. Geometric,
design group.
Chandelier, Mesh style,
Cake, Crown, Dice
51
D
(Digit)
2
1
D
-
-
3
Process
Main Material
A:Stamping A:Silver(Ag)
B:Casting
B:925 Sterling
C:Tubing
silver
C:Gold(Au)
4
-
Design Style
Design group
A: Animal (except human):- e.g. Dog,
Horse, Bird, Fish, Frog, Butterfly
B: Plant:- e.g. Tree, Leaf, Flower,
Fruit, Rose, Christmas tree,
5
6
7
Unique Number
001,002,003,...,999.
Use for classify
different design
style.
C: Star
D: Heart
E: Apparel:-e.g. Shoes, Shirt, Socks,
Trouser
F: Sports:- e.g. Golf, Football,
Basketball, Badminton
G: Musical:- e.g. Saxophone, Guitar,
Violin, Drum
H: Human and Manlike :- e.g. Man,
Woman, Boy, Santa Claus, Angel,
Sprite, Alien, Ghost
I: Letters or Numeral:- e.g. A, B, C, a,
b, c, 1, 2, 3
Z: Others (which cannot classify in
above design groups):- e.g.
Geometric, Chandelier, Mesh style,
Figure 4.11 Developed Semi-Jewelry Coding Structure (Translated from Thai)
4.2.7 Accessory coding structure: family “E”.
The accessory coding structure is composed of seven digits as shown in Figure
4.13. The meaning of each digit of family “E” can be explained as follows:
•
Digit 1: this digit must be “E” only
•
Digit 2: this digit represents the material uses for making an accessory.
The currently material available in the case study company included:
silver, 925 sterling silver, gold, copper, brass, and zinc which represent by
A, B, C, D, E, and F respectively
•
Digit 3: this digit represents the accessory shape such as ball, fish wire,
pin, and so on. This digit uses the alphabet A to Z, for example, the A
means ball shape, and B means fish wire shape
•
Digit 4: this digit represents the accessory size or detail, this is monocode
(or hierarchical structure which each digit amplifies the information
provided in the previous digit), the digit 4 amplifies the information
provided in the digit 3. For example, if the digit 3 is ball shape, the size of
the ball shape within the case study company are specify to be big size,
52
small size and no need to specify the exact size, and represented by A, B
and O respectively
•
Digits 5 to 7: these digits represent the supplier codes
Table 4.6 Example of Accessory: “E-BBA-020”
Meaning
Code in
Description for Code
Remark
Example
Family
E
Accessory
Accessory Material
B
925 Sterling silver
Accessory Shape
B
“Fish wire” shape
Accessory Size or
A
The size of this fish wire is
Detail
“SFF 07”.
(Length, Weight, etc.)
Supplier
The “020” code is
020
represented supplier named
“Why Wire co., ltd.”
E
(Digit)
-
-
1
2
3
4
5
- Accessory Material
A:Silver(Ag)
B:925 Sterling silver
C:Gold(Au)
D:Copper
E:Brass
F:Zinc
G:
H:
Accessory Shape
A:Ball
A:Big size
B:Small size
O: N/A
B:Fish wire
A:SFF 07
B:
C:
C:Pin
(Length, Weight, etc)
001:
002:
003:
004:
005:
006:
A:8 mm. (normally use on bend to fit)
I:
B:5 mm. (normally use on nose stud)
J:
C:11 mm. with 2 notches (normally use on earrings)
K:
D:22 mm. (normally use on nose spin)
L:
M:
D:Earring back
O:
P:
Q:
R:
S:
T:
U:
(for holding earrings) B:identify "925"
C:identify "925 CLE"
D:identify "925 AD"
E:
E:Pin with ball
A: 5 mm. with balls on both ends
F:
G:
A:No identify
Figure 4.12 Developed Accessory Coding Structure (Translated from Thai)
53
7
Supplier
Accessory Size or Detail
E
6
4.2.8 Ornament coding structure: family “F”.
The ornament coding structure is composed of thirteen digits as shown in
Figure 4.14. The meaning of each digit of family “F” can be explained as follows:
•
Digit 1: this digit must be “F” only
•
Digit 2: this digit represents the ornament material type such as acrylic,
rhinestone, cubic zirconia (CZ), plastic bead and so on. This digit uses the
alphabet A to Z, for example, A means the ornament material type is
acrylic, B means the ornament material type is rhinestone
•
Digits 3 to 4: these digits represent the ornament color. Due to each
ornament material type has different coloration, so the monocode (or
hierarchical structure) is used. The two digits (digits 3 and 4) amplify the
information provided in the digit 2. For example, if digit 2 is rhinestone,
the alphabet in the digits 3 and 4 mean color codes for rhinestone as
shown in Appendix C
•
Digits 5 to 7: these digits represent the ornament size. Due to each
ornament material type has different size, style and different measuring
system, so the monocode (or hierarchical structure) is used. The three
digits (digits 5 to 7) amplify the information provided in the digit 2. For
example, if the digit 2 is rhinestone, the alphabet in the digits 5 to 7 mean
size codes for rhinestone that used the standard “pp” and “ss” system. The
lists of “pp” and “ss” sizes are shown in Appendix D. (Remark: As
revealed in Rhinestone Guy, Inc, the “ss” stands for “stone size”, and the
“pp” stands for “pearl plate")
•
Digits 8 to 10: these digits represent the ornament shape. Due to each
ornament material type has different shapes, so the monocode (or
hierarchical structure) is used. The three digits (digits 8 to 10) amplify the
information provided in the digit 2. For example, if digit 2 is rhinestone,
the alphabet in the digits 8 to 10 mean the shape of rhinestone, the
developed codes for shaping system are applied by choosing the shapes
being in the case study company from the shaping list in the supplier
catalog
•
Digits 11 to 13: these digits represent the supplier codes
54
Table 4.7 Example of Ornament: “F-BA1P04-A01-002”
Meaning
Code in
Description for Code
Example
Family
F
Ornament
Ornament Material
B
Rhinestone (Synthetic gem)
Ornament Color
A1
Crystal color
Ornament Size
P04
The rhinestone size is “pp4”
Ornament
A01
MC CHATON shape
002
The “002” code is
Shape
Supplier
represented the supplier
named “Swarovski”.
55
Remark
F
(Digit)
-
2
1
F
-
Ornament
Material
A:Acrylic
B:Rhinestone
(Synthetic gem)
3
4
Ornament
Color
O0:without color
See the "Rhinestone Color
Codes"
5
6
-
7
Ornament
Size
OOO:without exact shape
Pn: size in "pp"
For example:
8
9
10
Ornament
Shape
O00:no need to specify
the same as Rhinestone
P03:pp3
Sn: size in "ss"
For example:
S01:ss1
C:CZ
A1:White
A2:Pink
D:Plastic bead
E:Pearl
A3:Dark Pink
A4:Lt. Pink
A5:Cream
A6:Black
A7:Golden brown
A8:Green
A9:Violet
B1:Lt. Blue
B2:Yellow
B3:Red
B4:Blue
B5:Orange
B6:Grey
B7:Brown
B8:
B9:
C1:
Rectangular Shape (for CZ only)
Format: "[_]X[_]", for example:
2
AXA: size 1 x 1 mm.
2
BXD: size 2 x 4 mm.
Round Shape
Format: "[_]O[_]", for example:
AOO: round, diameter 1 mm.
BOZ : round diameter 2.5 mm.
the same as CZ
the same as Rhinestone
O0: no need to specify
N:
O:N/A
P:
Q:
R:
S:
T:
U:
V:
W:
X:
Y:
Z:0.5 mm.
the same as CZ
the same as CZ
the same as CZ
I:Crystal bead
J:Silicone
K:Resin
L:Silver bead
the same as Rhinestone
the same as CZ
the same as CZ
the same as Rhinestone
the same as CZ
OOO:no need to specify
OOO:no need to specify
the same as CZ
M:Firado
the same as Rhinestone
O0:no color
(or no need to specify color)
Z9:
F:Cat eye
G:Glass
H:Hematite
A:1 mm.
B:2 mm.
C:3 mm.
D:4 mm.
E:5 mm.
F:6 mm.
G:7 mm.
H:8 mm.
I:9 mm.
J:10 mm.
K:11 mm.
L:12 mm.
M:
the same as Rhinestone
Figure 4.13 Developed Ornament Coding Structure (Translated from Thai)
56
CZ shape is used the same as Rhinestones
Ornament Shape for Plastic bead and Pearl
A00:Round-without hole
A01:Round-1 hole (block)
A02:Round-2 holes (go through)
B00:Square
C00:Triangle
D00:Cabochon
E00:Heart
F00:Star
G00:Marquise
H00:Oval
I00:Pear
J00:Half round
K00:Flower
L00:
M00:
O00:N/A
P00:
the same as CZ
the same as CZ
A02:Round-2 holes (go through)
(use shape codes of Plastic bead)
the same as Rhinestone
O00:no need to specify
The company will specify codes when to be used.)
A02:Round-2 holes (go through)
(use shape codes of Plastic bead)
O00:no need to specify
11
12
Supplier
001:
002:
003:
004:
005:
13
4.2.9 Material coding structure: family “G”.
The material coding structure is composed of seven digits as shown in Figure
4.15. The meaning of each digit of family “G” can be explained as follows:
•
Digit 1: this digit must be “G” only
•
Digit 2: this digit represents the material type uses by the case study
company. The currently available in the case study company included:
silver, 925 sterling silver, gold, copper, brass, zinc and plastic) which
represent by A, B, C, D, E, F, and G respectively
•
Digit 3: this digit represents the material shape such as granule, bar, wire,
sheet, and so on. This digit uses the alphabet A to Z, for example, the A
means granule shape, B means bar shape
•
Digit 4: this digit represents the material size, this is monocode (or
hierarchical structure which each digit amplifies the information provided
in the previous digit), the digit 4 amplifies the information provided in the
digit 3. For example, if digit 3 is granule shape, the size of granule shape
within the case study company is no need to identify and is coded as
alphabet “O”, and if digit 3 is wire size (which digit 3 is “C”), the digit 4
is represented size of wire which are called by numbering such as number
21, 22, 23, and so on
•
Digits 5 to 7: these digits represent the supplier codes
Table 4.8 Example of Material: “G-AAO-030”
Meaning
Code in
Description for Code
Example
Family
G
Material
Material Type
A
Silver(Ag)
Material Shape
AO
Material
O
Size
Supplier
Granule
N/A. Do not have the exact
size for granule shape
030
The “030” code is
represented supplier named
“Silver Expert co., ltd.”
57
Remark
G
(Digit)
-
-
1
G
2
-
3
4
Material
Material
Type
Shape
A:Granule
A:Silver(Ag)
B:925 Sterling silver B:Bar
C:Wire
C:Gold(Au)
D:Copper
E:Brass
F:Zinc
G:Plastic
Material
Size
O: N/A
H:Silver Solder
F:No. 26
5
6
7
Supplier
-
A:No. 21
B:No. 22
C:No. 23
D:No. 24
E:No. 25
001:
002:
003:
004:
005:
006:
I:
D:Sheet
O: N/A
E:Powder
O:N/A
Figure 4.14 Developed Material Coding Structure (Translated from Thai)
4.2.10 Label and sticker coding structure: family “L”
The label and sticker coding structure is composed of eleven digits as shown
in Figure 4.16. The labels and stickers of the case study company are used based on
the customer product code. The meaning of each digit of family “L” can be explained
as follows:
•
Digit 1: this digit must be “L” only
•
Digit 2: this digit represents the label and sticker types such as barcode,
and others that will be expanded in the future use. This digit uses the
alphabet A to Z, the A means barcode
•
Digits 3 to 8: these digits represent the customer product codes. If
customer product codes are less than 6 digits, “0” will be placed preceding
digits to form 6 digits. For example, customer product codes are “4674”,
“00” will be placed, the digits 3 to 8 will be “004674”
•
Digits 9 to 11: these digits represent the supplier codes
58
Table 4.9 Example of Label and Sticker: “L-A073528-040”
Meaning
Code in
Description for Code
Remark
Example
Family
L
Label and Sticker
Label and Sticker
A
Bar code
Type
Customer Product
073528
Code
The customer product code
is “73528”
Supplier
040
The “040” code is
represented the supplier
named “Joho co., ltd.”
L
(Digit)
-
-
1
L
2
-
Label and Sticker
Type
A:Bar code
B
C:
D:
E:
F:
3
4
5
6
7
8
9
10
11
Supplier
Customer Product Code
000000: For label or sticker that
without customer product code
Note: In case of customer product
code is less than 6 digits, "0" will be
placed preceding digits to form 6 digits.
001:
002:
003:
004:
005:
006:
G:
H:
I:
For example:
o Customer Product Code is "4674".
These digits (3 to 8) will be "004674"
Figure 4.15 Developed Label and Sticker Coding Structure (Translated from Thai)
4.2.11 Packing material coding structure: family “P”.
The packing material coding structure is composed of six digits as shown in
Figure 4.17. The meaning of each digit of family “P” can be explained as follows:
•
Digit 1: this digit must be “P” only
•
Digit 2: this digit represents the packing material types such as adhesive
tape, bubble sheet, carton, plastic strapping band, and so on. This digit
uses the alphabet A to Z, for example, the A means adhesive tape, B
means bubble sheet
59
•
Digit 3: this digit represents the packing material size, this is the
monocode (or hierarchical structure which each digit amplifies the
information provided in the previous digit), the digit 3 amplifies the
information provided in the digit 2. For example, if the digit 2 is “C”
(carton) which size is equal to 29x40x15 cm3 then the digit 3 is “A”, and
so on
•
Digits 4 to 6: these digits represent the supplier codes
Table 4.10 Example of Packing Material: “P-FB-010”
Meaning
Code in
Description for Code
Example
Family
P
Packing Material
Packing Material
F
Zip lock bag
B
The zip lock bag size is
Type
Packing Material Size
4"x6"
Supplier
010
The “010” code is
represented supplier named
“Jewelry Pack co., ltd.”
60
Remark
P
(Digit)
-
-
1
P
2
-
Packing Material
Type
A:Adhesive Tape
B:Bubble sheet
C:Carton
3
4
Packing Material
Size
A: width 2"
A: 2"x5"
5
6
Supplier
001:
002:
3
A: 29x40x15 cm
3
B: 40x35x61 cm
3
C: 51x51x50 cm
3
D: 65x65x65 cm
3
E: 50x30x30 cm (UK)
003:
004:
005:
006:
3
F: 60x50x45 cm (UK)
D:Plastic Strapping Band
A: width 20 mm.
E:Plastic bag
A:3"x4"
F:Zip lock bag
B:4"x6"
C:6"x8"
D:7"x10"
E:7"x11"
F:8"x12"
G:9"x12"
H:9"x13"
I:10"x5"
J:10"x6"
K:13"x20"
L:16"x24"
M:
N:
O:N/A
Q:
G:White foam
A:thickness 5 mm.
H:Black foam
Figure 4.16 Developed Packing Material Coding Structure (Translated from Thai)
4.2.12 Software use for product classification and coding in the case study
company.
To assign the codes to products and ensure that the product codes were not
duplicated, the database software for assigning, keeping and retrieving the product
codes, was needed. The database for the product classification and coding in the case
study company was developed by using the Microsoft Access 2003, as shown in
Figures 4.18 to 4.26.
61
Figure 4.17 Products Coding Main Menu
Figure 4.18 Finished Goods (Family “A”) Menu
62
Figure 4.19 Jewelry (Family “B”) Menu
Figure 4.20 Card (Family “C”) Menu
63
Figure 4.21 Semi-Jewelry (Family “D”) Menu
Figure 4.22 Accessory (Family “E”) Menu
64
Figure 4.23 Ornament (Family “F”) Menu
Figure 4.24 Material (Family “G”) Menu
65
Figure 4.25 Label and Sticker (Family “L”) Menu
Figure 4.26 Packing Material (Family “P”) Menu
4.3 Development of Production Traceability System
As revealed in the Chapter 2, the needed information is dependant on the
purposes of the production traceability, (METI, 2003; Steele, 1995). The reviewed
literatures were adapted to identify the purposes of the production traceability in this
development. The case study company main purposes of the production traceability
were identified according to the company requirements and problems. The main
purposes are included: traceable to the outsourcers who make the defects, ability to
66
tracing the product type and the production route to prevent loss in the sterling silver
that given to the outsourcers, and prevent the contaminated metal (like lead or nickel)
in the jewelry by tracing back to the metal material sources that were used.
Steele (1995) suggested that to design a production traceability system,
required the unique identification for the physical lot, the data recoding for the lot
movement, lot-process linking to the process data, and reporting that retrieves the lottracing data from the system to find the source lots or component materials associated
with the suspected lot.
Steele’s (1995) methodology to design a production
traceability system was used, the details are as follows:
4.3.1 Unique identification for physical lot.
Steele (1995) suggested that:
A lot is a physical grouping of material that control as a unit. ... Tracking the
lots, the component material used in them, their transformation to or inclusion
in other lots, and, finally, their use as a shipped item is the primary function of
traceability. How lots are defined and controlled is an essential design
question. (p. 53)
The main physical lots in the case study company are identified as follows:
1) Finished goods and its work-in-process lots are identified by the lot
numbers (lot no.), which divided from the customers’ purchase order
numbers into subgroups. The lot numbers are structured by the customers’
purchase order numbers follow by the subgroup numbers.
2) The purchased parts (or materials), such as silver, copper, silver wires and
so on, the lots are identified by the received date as the main physical lot
identification.
3) The lots of manufactured parts are identified by their manufactured date.
4.3.2 Data recording for lot movement.
Two types of data were collected; the lot tracing data and the process data.
The lot tracing data recorded the movement of lots from materials or parts that might
be merged or transformed from one lot into another lot. The process data recorded the
important production process information, which usually depends on their original
67
purposes. Regardless of how the data are collected, manual or electronics, or local or
network, the lot records and the process data must be linked (Steele, 1995).
In the case study company, the data recording for lots movement were
developed according to the company purposes for production traceability that
included: traceable to the outsourcers who make the defects, ability to track and trace
the product types and the production routes to prevent loss in the sterling silver that
given to the outsourcers, and prevent the contaminated metal (like lead and nickel) in
the jewelry by tracing back to the metal material sources that were used. The mostly
important purpose at the time system being developed is the contaminated metal.
From the collected data, especially the interviews, the contaminated metal could cause
from the purchased material such as silver, copper, or caused from the outsourced
processes. The process besides the main three processes; tubing, stamping, and
casting, is considered and could caused contaminated metal was the pin making
process which one lot of pins was used in many lots of products. The data recording
forms for tracking the lot movement of finished goods and work-in-process in these
process routes were developed as shown in Figures 4.28 to 4.33.
68
Lot Movement Tracking in Main process
Lot no.: __________________
[__] adding quantity, referred to new order running no. _____________
Finished Goods Code: A-__ __ __ __ - __ __ __ __ __
Quantity: _______ pairs, Total:______ pieces
Process Step
[__] new order
Running No.:__________
Delivery Date: ___________________
Start - Finish Date
Operator/
Outsourcer
Record for Traceability
O Weighing
O Weigh per piece _____ g. Quantity ______ pieces Weigh _____ g.
O Polishing
O Antique-treatment process
O Cleaning antique-treatment
O Weighing
O Coloring process
O Start time: _______ Finished time: _______
O Total weigh __________ g.
O Color Detail:_____________________________________________
O Quantity __________________ pieces Total weigh ___________ g.
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
O Stone setting process
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
Return Ornaments to Stock
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
O Quantity counting and recording
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
O F- __ __ __ __ __ __ - __ __ __ - __ __ __ Date on package: _________
O Final polishing and Anti-tarnish
coating
O Start time: _______ Finished time:_______
O Product weighing
O Total weigh __________ g.
O Sampling Check
O Sampling quantity:_______ piece, Damage quantity: _____ pieces, Symptom: ________________
O Jewelry stock keeping
Figure 4.27 Developed Traceability Recording Form (Main Process) (Translated from Thai)
69
Lot Movement Tracking in Tubing Process
Lot no.: __________
Style no.: ___ ___ ___ ___ ___
Semi-jewelry Code: D-__ __ - __ __ __ __
Process Step
O Silver and copper
mixing
Start - Finish Date
[__] new order
[__] adding quantity, referred to new order running no. _____________
DM#: _______________
Running no.:__________
Order Quantity: _______ pairs, Total: _________pieces
Operator/
Outsourcer
Delivery Date: ___________________
Record for Traceability
O Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Total ________g.
O Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Total ________g.
O Leftovers "95 Silver" ____________ g. From Running no.: __________
Leftovers "95 Silver" ____________ g. From Running no.: __________
Total ________g.
Leftovers "95 Silver" ____________ g. From Running no.: __________
Grand Total ________
g.
O Silver and copper
melting
O Forming into string
O Pressing into sheet
O Rolling sheet to
form tube
O Rolling tube around
the axis like a spring
O Attaching a holding
pin
O Return the leftovers
silver and copper
mixed
O Wire no.:__ Code: E- __ __ __ - __ __ __ Date on package: _____
O Silver solder date on package: _______
O Leftovers weigh __________ g. (Identify "Running no." of this document on the leftovers package)
Figure 4.28 Developed Traceability Recording Form (Tubing Process) (Translated from Thai)
70
Lot Movement Tracking in Stamping Process
Lot no.: __________
Style no.: ___ ___ ___ ___ ___
Semi-jewelry Code: D-__ __ - __ __ __ __
Process Step
O Silver and copper
mixing
Start - Finish Date
[__] new order
[__] adding quantity, referred to new order running no. _____________
DM#: _______________
Running no.:__________
Order Quantity: _______ pairs, Total: _________pieces
Operator/
Outsourcer
Delivery Date: ___________________
Record for Traceability
O Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Total ________g.
O Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Total ________g.
O Leftovers "95 Silver" ____________ g. From Running no.: __________
Leftovers "95 Silver" ____________ g. From Running no.: __________
Total ________g.
Leftovers "95 Silver" ____________ g. From Running no.: __________
Grand Total ________
O Silver and copper
melting
O Pressign into sheet
O Silver stamping
O 925 Silver (G-BDO-__ __ __ ) weigh (give to oursourcer) : __________ g.
O Checking compare
to design
O Attaching a holding
pin
O Return the leftovers
silver and copper
mixed
O Pin code E- __ __ __ - __ __ __ Date on package: _____
O Silver solder date on package: _______
O Leftovers weigh __________ g. (Identify "Running no." of this document on the leftovers package)
Figure 4.29 Developed Traceability Recording Form (Stamping Process) (Translated from Thai)
71
g.
Lot Movement Tracking in Casting Process
Lot no.: __________
Style no.: ___ ___ ___ ___ ___
Semi-jewelry Code: D-__ __ - __ __ __ __
Process Step
[__] new order
[__] adding quantity, referred to new order running no. _____________
DM#: _______________
Running no.:__________
Order Quantity: _______ pairs, Total: _________pieces
Start - Finish Date
Operator/
Outsourcer
Delivery Date: ___________________
Record for Traceability
O New model making
O Rubber mold making
O Wax spueing
O Quantity (wax models) _______pieces
O Wax tree making
O Quantity (wax tree) _____trees, total (wax models) _________ pieces
O Investing
O Mixing and melting
silver and copper into lime
mold
O Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Total ________g.
O Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Total ________g.
O Leftovers "95 Silver" ____________ g. From Running no.: __________
Total ________g.
Leftovers "95 Silver" ____________ g. From Running no.: __________
Leftovers "95 Silver" ____________ g. From Running no.: __________
Grand Total ________
g.
O Silver tree casting
O Cleaning silver tree by
dipping into acid
O Weigh the total silver
tree
O Cut silver branches
from silver core
O Weigh the total silver
tree
O Cleaning silver branches
O Quantity _____trees Total weight __________ g.
O Quantity _____trees Total weight __________ g.
O Total quantity ________ pieces
O Total quantity ________ pieces
O Branch weight _________ g. Core weight __________ g. Base weight __________ g.Total weight __________ g.
O Total weight___________ g.
O Cut silver pieces from
branches
O Sent weight _________ g. Return weight __________ g. Total pieces __________ pieces
O Polishing
O Total weight (after polishing) ______________ g.
O Attaching a holding pin
O Pin code E- __ __ __ - __ __ __ Date on package: _____
O Return the leftovers
silver and copper mixed
O Leftovers weigh __________ g. (Identify "Running no." of this document on the leftovers package)
O Defect quantity __________ pieces, symptom: _____________________________________________________
O Silver solder date on package: _______
Figure 4.30 Developed Traceability Recording Form (Casting Process) (Translated from Thai)
72
Lot Movement Tracking in Packing process
Lot no.: __________ Finished Goods Code: A-__ __ __ __ - __ __ __ __ __ Delivery Date: __________
Running no.:__________
Attached the sample "Label":
Process Step
Start - Finish Date
Operator/
Outsourcer
Record for Traceability
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
O Requesting jewelry from stock
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
Return Jewelry to stock (Leftovers)
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
O B- __ __ - __ __ __ __ - __ __ - __ __ __ __ __ __Date on package: ________ Qty. ______pcs.
O Requesting finished card from
stock
O Packing jewelry on finished
card
O C- __ __ __ __ __ __ - __ __ __
Date on package: ______ Qty. ______pcs.
O C- __ __ __ __ __ __ - __ __ __
Date on package: ______ Qty. ______pcs.
O Finished goods quantity ____________ pieces
O Finished goods quantity ____________ pieces
O Finished goods quantity ____________ pieces
O Finished goods quantity ____________ pieces
O Finished goods quantity ____________ pieces
O Count and prepare to export
O Pack in plastic bags ________ pieces, Total of bags _____________ bags
Figure 4.31 Developed Traceability Recording Form (Packing Process) (Translated from Thai)
73
Total_____pieces
Lot Movement Tracking in
[__] Wire Making Process or [__] Pin Making Process (Choose one by marking "/")
Order request no.: __________________
Running no.:__________
Quantity: _______ pairs
Process Step
Start - Finish Date
Operator/
Outsourcer
Record for Traceability
Wire Making Process
O Silver and copper mixing
O Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Silver granule (G-AAO-__ __ __ ) Lot date: ________, Weigh
+
g.
O Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Copper granule (G-DAO-__ __ __ ) Lot date: ________, Weigh
+
g.
Total ________g.
Total ________g.
O Leftovers "95 Silver" ____________ g. From Running no.: __________
Total ________g.
Leftovers "95 Silver" ____________ g. From Running no.: __________
Leftovers "95 Silver" ____________ g. From Running no.: __________
Grand Total ________
O Silver bar casting
O Forming into wire
O Wire no.___Code G- __ __ __ - __ __ __
Wire no.___Code G- __ __ __ - __ __ __
Wire no.___Code G- __ __ __ - __ __ __
Wire no.___Code G- __ __ __ - __ __ __
Wire no.___Code G- __ __ __ - __ __ __
Wire no.___Code G- __ __ __ - __ __ __
Total _____g.
O Keep into stock
O Return the leftovers silver
and copper mixed
O Leftovers weigh __________ g. (Identify "Running no." of this document on the leftovers package)
Pin Making Process
O Request silver wire from
stock
O Wire no.___Code G- __ __ __ - __ __ __ Date of package: ____________
O Pin making by machine
O Machine no: MC#____
Total _____g.
O Quantity of packs _____ packs, Weight per pack _____g. Quantity per pack _____pairs
O Weighting and packing
Total______g.
Quantity of packs _____ packs, Weight per pack _____g. Quantity per pack _____pairs
O Recorded damage wires
O Quantity _________ g. Symptom: _________________________________________
Figure 4.32 Developed Traceability Recording Form (Pin Making Process) (Translated from Thai)
74
g.
4.3.3 Lot-process linking to the process data.
These are the processes or parts (or materials) data linked to the physical lots.
On the other hand, it is the method that process data are identified with a
corresponding production lots. The direct way to link the data are the lot identification
numbers, by recording the same lot identification number on both the physical lot
tracing and the process data. For example, raw materials can be performed by (1)
recorded by lot number, (2) marked directly on parts, or (3) link by time and date. The
major advantage of linking by time and date is that it is not complicated, and does not
require existing system to be tied together. The major disadvantage of linking by time
and date is that it is required time-consuming to retrieve the lot-tracing data. (Steel,
1995) The developed system in the case study is used both the time-date linking and
the lot number linking.
4.3.4 Reporting that retrieves the lot-tracing data from the system.
Steele (1995) suggested that the design of the reporting function was
considered by how data were stored, the access frequency, the permitted retrieval
time, and storage space limitations. If all data were kept in a computerized system,
data might be fully accessible under almost any conditions. If the data were not
accessed frequently and long access time is permitted, automated retrieval may not be
necessary. Simple manual filing of key data with well organizing might be sufficient.
Cross linking by time and date was suggested for manual retrieval. However, in any
cases, there must be planned for storage spaces for several years of data, electronics or
physical.
As the case study company, at the period of the system start up, the key data
were stored by manual filing. This is because the company had few types of
documents, the data are not needed to be in real time for accessing, and the employees
lack experience in using computerize systems. (The maintenance and update
information in the software for traceability is more complicated than the product
classification and coding system.) The manual stored data of the case study are
organized by using the data storage control forms (or record control form) for
retrieval of the data, the forms’ information included: where the data were kept, how
the data were filed, who responsible person is, and retention period for data storage.
The record control form is shown in Figure 4.34.
75
Data Storage Control
Prepared by: ..................................... Approved by: ....................................... Date: ......./........./......
Item
Description
Storage Place
Indexing
Responsible
By
page: ...../.....
Retention Period
Figure 4.33 Data Storage Control Form (or Record Control Form)
4.4 Result of System Application and User’s Satisfaction
The developed prototype of the system was field-tested by sampling the
company’s customer purchase orders that were producing to investigate the
operational and the practical use. The company executive; managing director, was
asked for satisfaction by through the questionnaire, the results are shown in Figure
4.35.
76
For Product Classification and Coding
Items
1. Comparing to your previous system, the product classification and
coding system is better than previously.
2. After used this system, please rates the following items:
- ease of use
- easy to understand
- usefulness
- enough information of the product attributes on code.
- flexibility for various applications such as warehousing, designing,
production planning and so on.
- accuracy, to provide correct information on products, parts and
materials.
3. The product classification and coding system is suitable for
implementing in your company.
Score
4
4
3
5
4
4
4
4
For Production Traceability
Item
1. Comparing to your previous system, the production traceability system
is better than previously.
2. After used this system, please rate the following items:
- ease of use
- easy to understand
- usefulness
- quick to access the traceability information
- flexibility for various applications such as production planning,
purchasing, quality control and so on.
- accuracy of the system to provide correct information
3. The production traceability suitable for implementing in your company.
Score
5
4
4
4
5
4
4
4
In Summary
Item
1. The system contributes to reduce extra costs from the loss main material
to outsourcers.
2. The traceability system helps to reduce the quantity of suspected
products.
3. The system helps to improve the product quality.
4. In overall, you satisfy with the product classification and production
traceability system.
Figure 4.34 The Company Executive Rating Score
Note: Rating range from 1 to 5,
Strongly disagree
=
1
Disagree
=
2
Neither agree nor disagree
=
3
Agree
=
4
Strongly agree
=
5
77
Score
3
5
4
4
The item scored less than “3” is considered “not pass” in this case. For the
product classification and coding system, the company executive scored this system
as quite satisfactory, except the “easy to understand” item which was scored “neither
agree nor not agree” with the added comment that it is easy for executive to
understand but the employees needed to have more knowledge. Therefore, this should
be considered for formal training of the company staff members. For the production
traceability system, the company executive also scored this system quite satisfactory,
especially compare to the previous system, and the system is quick to access the
traceability information. For overall system, the company executive scored this
system as quite satisfactory, except the “system contributes to reduce extra costs from
the loss main material to outsourcers” item was rated “neither agree nor not agree”.
However, in overall, the company executive satisfied with the product classification
and the production traceability system which was scored as “agree”. From this result,
the conclusion that the system was effective and the company could get the
advantages from this system.
4.5 Recommend Action for Further Software Development in the Case Study
Because of the rapid growth of the case study company, in the next coming
year, the company’s data and documents will be increasing and may need to be
accessed faster and frequently and company planned to train the currently employees
to be able to use the computerize system and, if necessary, the company may recruit
new employees. In the future, the data for production traceability should be stored in
computerized system; therefore, the requirements for future software development to
use for the production traceability should be based on the currently manual
traceability system with the further development on its weak point.
78
Chapter 5
Conclusions and Recommendations
In this chapter, the conclusions and recommendations for further study are
discussed.
5.1 Summary and Conclusions
The product classification and production traceability system was developed
by following steps: study the case study company process and products by reviewing
document, interviewing, direct observing at the research site, and investigate the
company’s products, parts and materials. The product classification system was
developed by using the group technology classification and coding theory, the mixed
code or hybrid structure was chosen to be applied. The coding structure of products,
parts, and materials are composed of six to fifteen digits depend on the product
family, the first digit informed about the product family that can be group according
to its similar attributes. The product codes of each family were recorded in the
database that writing from the Microsoft Access 2003 application. The production
traceability system was developed by identifying the company requirements
according to the problem face and foresee for the future prevention. Steel (1995)
methodology was used which included: unique identification for physical lot, data
recording for lot movement, lot-process linking to process data, and reporting which
retrieved the lot-tracing data system to find source lot and suspected lots. The unique
identification of lot was identified by the lot number and date. The production
traceability had ability to trace to the history of products about the outsourcers who
produced it, the parts and materials that were used and the main material quantities
that used in the major processes. The process data for traceability were kept manually.
The prototype of developed product classification and production traceability system
was field-tested and the company executive was satisfied with some comments that
had the advantages for further development.
5.2 Research Difficulties and Limitations
The top management of the case study company has strong intention to
develop the system. The product classification and production traceability is one of
79
the systems that the management prefers to have. The thesis did not find much
difficulties or limitation in terms of support.
However, there are some difficulties and limitations that are listed as follows:
There is inadequate documentation in the case study company, while the
developed system required more documentation. But the production tasks are still
operated by the workers’ skills and memories. To fully develop the documentation in
the case study company needs more time, however, the research period was limited.
Some technical terms that are used by the production of the case study
company is specific and different from other jewelry companies. The researcher needs
to learn and understand these specific technical terms in order to use these technical
terms to develop the system.
It is a difficult to implement the developed coding system because the workers
have limited education and are familiar with the existing system. Hence they have
difficulty in adjusting their habits to perform their tasks according to the new system.
5.3 Recommendations for Further Development
This study concentrates on the fashionable sterling silver jewelry that is
decorated with non-precious ornaments such as synthetic gems, acrylic, imitated
pearl, plastic and so on. The product classification structure and production
traceability systems for other jewelry businesses needs to be adapted or may be
completely different. The recommendations for further development are proposed as
follows:
1) The development of product classification and production traceability in
other jewelry businesses such as gold jewelry.
2) The development of product classification and production traceability for
the precious gems which have more complicated attributes and need to
trace back to the country of origins (which are the regulation in some
countries).
80
References
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83
Appendix A
Interview Guidance: Company Management and Employees
1. How many employees does the company have?
2. What are the company’s products? Please explain in details.
3. What are the problems that usually occurred? How do you handle them?
4. What are the main parts or materials?
5. Which parts or materials are important and the most effect to the product quality?
6. Please explain the details of parts (or materials) attributes?
7. How do you plan the production?
8. How does the production process start and end? Please explain.
9. Which process steps are outsourced?
10. What are the documents that used in the production process?
11. What are the records that used in the production process?
12. What attributes of products do you think are important and needed to be
traceable?
13. What kinds of information would you like to include in the product (or part, or
material) codes?
14. Do you have any suggestion about the production information that needs to be
traceable?
15. Does the company use any supplier or customer codes? If have, please explain.
16. Does the company use any coding systems? If have, please explain.
17. What are the computer facilities and software that currently be used by company?
18. What are the expected purposes of the production traceability?
84
Appendix B
Interview Guidance: Gemology Expert
1. Are there any international or standard classification systems for gem and
synthetic gem, especially the rhinestone like Swarovski?
2. Are there any international or standard classification systems for jewelry and
silver jewelry?
3. Does the Swarovski coding system standardize?
4. What are the problems that usually occur to the silver jewelry? How do these
problems occur?
5. Is there any identification on gems or jewelry?
6. What attributes of silver jewelry do you think are important and needed to be
traceable?
7. Do you have any suggestions about the production information that needs to be
traceable?
85
Appendix C
Example of Rhinestone Color Code
Code
Color
Code
Color
Code
A1
A2
A3
A4
A5
A6
A7
A8
A9
B1
B2
B3
B4
B5
B6
B7
B8
B9
C1
C2
C3
C4
C5
C6
C7
C8
C9
D1
D2
D3
D4
D5
D6
D7
D8
D9
Crystal
Shadow Crystal
Black Diamond
Morion
Light Azore
Aquamarine
Light Sapphire
Idian Sapphire
Sapphire
Capri Blue
Montana
Chrysolite
Peridot
Erinite
Indicolite
Blue Zircon
Emerald
Tumaline
Jonquil
Light Topaz
Khaki
Lime
Olivine
Fireopal
Padparadscha
Hyacinth
Indian Red
Light Siam
Siam
Ruby
Garnet
Burgundy
Light Peach
Light Colorado Topaz
Topaz
Light Smoked Topaz
E1
E2
E3
E4
E5
E6
E7
E8
E9
F1
F2
F3
F4
F5
F6
F7
F8
F9
G1
G2
G3
G4
G5
G6
G7
G8
G9
H1
H2
H3
H4
H5
H6
H7
H8
H9
Smoked Topaz
Smoky Quartz
Light Rose
Rose
Fuchsia
Light Amethyst
Violet
Tanzanite
Amethyst
White Opal
Pacific Opal
White Alabaster
Jet
Turquoise
Rose Alabaster
Crystal Aurore Boreale (AB)
Crystal Satin
Crystal Comet Argent Light
Crystal Mat-Finish
Crystal Vitrail Light
White Opal Sky Blue
White Opal Star Shine
Crystal Bermuda Blue
Crystal Heliotrope
Crystal Metallic Blue
Crystal Dorado
Jet Hematite
Jet Metallic Silver
Jet Nut
Crystal Vitrail Medium
Green Flare
Sahara
Volcano
Blue Flare
Blue Hematite
Bermuda Blue
I1
I2
I3
I4
I5
I6
I7
I8
I9
J1
J2
J3
J4
J5
J6
J7
J8
J9
K1
K2
K3
K4
K5
K6
K7
K8
K9
L1
L2
L3
L4
L5
L6
L7
L8
L9
86
Color
Silver Flare
Blown Flare
Sun
Heliotrope
Aqua Bohemica
Citrine
Hematite
Lablador
Aurum
Vitrail Light
Marea
Vitrail Green
Sapphire AB
Light Siam AB
Aquamarine AB
Code
M1
M2
M3
M4
M5
M6
M7
M8
M9
N1
N2
N3
N4
N5
N6
N7
N8
N9
O1
O2
O3
O4
O5
O6
O7
O8
O9
P1
P2
P3
P4
P5
P6
P7
P8
P9
Color
Appendix D
The Standard Rhinestone Size
87
Source: Adapted from Preciosa (2006)
88
Biography
Name:
Achara Satayapaisal
Year of Birth:
March 5, 1967
Place of Birth:
Bangkok, Thailand
Institutions Attended:
Year 1986 - 1990
Bachelor of Engineering in Electronics
King Mongkut’s Institute of Technology Ladkrabang
Bangkok, Thailand
Year 2003 - 2005
Bachelor of Public Health in Occupational, Health and
Safety
Sukhothai Thammathirat Open University
Nonthaburi, Thailand
Year 2006 - 2007
Bachelor of Business Administration in Marketing
Sukhothai Thammathirat Open University
Nonthaburi, Thailand
Year 2006 - 2007
Master of Science in Management
Shinawatra University
Bangkok, Thailand
Home Address:
218 Bondstreet Road, Pakkred, Nonthaburi, Thailand
Telephone:
(66)8 1792 0715
89