YAMAHA MOTORS Seminar(SKYLINE)

History

If you're going to do something, be the

best.
from these words spoken by Genichi
kawakami (Yamaha Motor's first
president) built the company in 1953.
August of 1954 the first model was
complete. It was the Yamaha YA-1. The
bike was powered by an air-cooled, 2stroke, single cylinder 125cc engine

Paving the Road to Yamaha Motor Corporation

YAMAHA MOTORS Seminar(SKYLINE)

YAMAHA MOTORS PRIVATE

LIMITED

Yamaha motors is amongst the most

popular bike manufacturers in India.
The company has given some most
successful bikes like RX100 to Indian
roads and is a tough competitor for
other biking giants. A wide variety of
models in all categories of
motorbikes, Yamaha is the all time
great brands to rely upon.

Presently 14 models are available from

Yamaha's garage in India

YAMAHA MOTORS Seminar(SKYLINE)

Bikes produced in India Yamaha Motor Pvt.

Ltd. :

Vmax

mt01

r1

r15

fazer

fzs

YAMAHA MOTORS Seminar(SKYLINE)

Fz 16

ybr 100 alba gladiator

g5 crux

YAMAHA MOTORS Seminar(SKYLINE)

ABOUT THE CONCERNED DEPARTMENT:

Material Management Group- Purchase
Planning
Supply chain
Supply chain management
Tasks of supply chain management
i. Building a Strategic Framework
ii. Designing the Supply Chain Network.
iii. Planning Demand and Supply.
iv. Planning and Managing Inventories
Hence the purpose of supply chain management is to
improve trust and cooperation among supply chain
partners, thus improving inventory visibility and speed

YAMAHA MOTORS Seminar(SKYLINE)

Supply Chain Management

Problems

Distribution Network Configuration

Distribution Strategy:
Trade-Offs in Logistical Activities:
Information
Inventory Management:
Cash-Flow:

Trade-offs are key to developing the most efficient and

effective Logistics and SCM strategy.

Materials management
Few tasks undertaken by Material Management :

Quality Assurance
Standards
Improving circulation infrastructure

Materials management is the branch of logistics that

YAMAHA MOTORS deals with the tangible
components of a supply chain.
Seminar(SKYLINE)

YAMAHA MOTORS Seminar(SKYLINE)

Quality Assurance

A large component of materials management is

ensuring that parts and materials used in the
supply chain meet optimum quality requirements
by performing Quality Assurance (QA).
Parts and material are tested, both before
purchase orders are placed and during use, to
ensure there are no short or long term issues that
would disrupt the supply chain.
This aspect of material management is most
important for heavily automated industries, since
failure rates due to faulty parts can slow or even
stop production lines, throwing off timetables for
production goals.
THUS QA HAS A VERY IMPORTANT ROLE IN MAINTAINING THE
BRANDS GOOD WILL AND PRODUCT RELIABILITY

YAMAHA MOTORS Seminar(SKYLINE)

Standards

There are standards that are followed in

supply chain management that are critical to a
supply chain's function
For example, a supply chain that uses just-intime or lean replenishment requires absolute
perfection in the shipping of parts and
material from purchasing agent to warehouse
to place of destination.
Systems reliant on vendor-managed
inventories must have up-to-date computerized
inventories and robust ordering systems for
outlying vendors to place orders on
IYM follows Just in Time strategy for supply chain

YAMAHA MOTORS Seminar(SKYLINE)

Improving circulation
infrastructure

Redundancy can be reduced and effectiveness is

increased when service points are clustered to
reduce the amount of redundancy
Solutions can include creating a new central
loading location, as well consolidating service
areas and docks from separate buildings into one.
Developing better campus circulation
infrastructure also means re-evaluating truck
delivery and service vehicle routes
Vehicle type, size, and schedules are studied to
make these more compatible with surrounding
neighborhoods

An institutional campus, office, housing complex will also

get the highest and best use out of campus real estate.

YAMAHA MOTORS Seminar(SKYLINE)

Purchasing management

Purchasing management is the management of

purchasing process, and related aspects in an
organization. Because of production
companies purchase nowadays about 70% of
their turnover, and service companies
purchase approximately 40% of their turnover,
purchasing management is one of the most
critical areas in the entire organization and
needs intensive management.

assigning purchasing tasks to employees

YAMAHA MOTORS Seminar(SKYLINE)

Purchasing Process

Purchasing Process includes as usual 8 main stages

as follows:
i. Requisitioning
ii. Approving
iii. Studying Market
iv. Making Purchase Decision
v. Placing Orders
vi. Receipting Goods and Services Received
vii.Accounting Goods and Services
viii.Receiving Invoices and Making Payment
ix. Debit note in case of material defect

Setting task priorities, start/finish dates etc.

YAMAHA MOTORS Seminar(SKYLINE)

LOGISTICS

It is the duty of logistics department to ensure the

transport facilities to carry goods across the
companys network in a manner most efficient in
operation and most reasonable in expenditure.
The contracts and agreement papers are prepared
by the legal team of the company along with the
assistance of the concerned department to ensure
that the company is safe from all potential types
of fraud and legal manipulations apprehended
while doing business with another company.
This also facilitates the growth of healthy business
relationship and cooperative environment among
the companies involved for the purpose of
outsourcing different aspects of the central
company.
agreements are prepared as meticulously as possible to
ensure that the organization is shielded

YAMAHA MOTORS Seminar(SKYLINE)

Form 38

Form 38 belonging to Sales Tax Dept. is the

proof to the government that the company
has asked the particular transporter to bring
in or carry away certain consignment.
It is the duty of the Finance Dept. to issue
booklet containing Form 38 to the Purchase
Dept., and the record of Form numbers of the
issued forms has to be kept properly.
Upon the delivery of goods by a vehicle, its
corresponding form 38 (filled) is returned to
the Stores Department which receives the
brought goods as well. The store then
returns the forms to the Finance
Department.
THERE R SEVEN STAGES IN THIS PROCESS

YAMAHA MOTORS Seminar(SKYLINE)

Sale tax
office

Finance
Deptt.

Gate

Purchas
e Deptt.

Vendor

/stores

The 7 stages

/
transport
er

YAMAHA MOTORS Seminar(SKYLINE)

COSTING

The IYM follows a robust costing exercise to

ensure lowest possible material and parts cost,
while outsourcing the manufacture of
assemblies, sub-assemblies and various
components through over 200 companies
For effective management and better work
distribution, the parts have been categorized into
8 major categories:
Sheet Metal
Turned Parts
Hardware
Rubber
Plastic
Proprietary
Electrical
Casting

the engineers strive to know every minute detail directly or

indirectly associated with the money involved in manufacturing

YAMAHA MOTORS Seminar(SKYLINE)

PRICE REVISIONA REGULAR ACTIVITY

Once the cost pertaining to manufacturing

processes, transportation and overheads
is established, they are considered to be
constant (but are variable under special
cases). Then only the current price of raw
material is the benchmark factor and is
varying daily or quarterly/yearly. Thus
the existing price of raw material is taken
as the basis for quarterly revision of cost
of the part manufactured by the vendor.
This is known as the policy of price
revision.
Different vendors have different beginning months
for cycles of price revision.

YAMAHA MOTORS Seminar(SKYLINE)

IMPACT SHEET

It is the data represented in tabular form. It essentially

contains data about change in price of various products
on the basis of many factors like change in the price of
raw material, operation cost, turning cost, tool cost and
other over head charges.
Content of impact sheet

Part number
Part name
S.O.B
existing price
Revised price
Impact
Effect
Effective volume
Total impact

YAMAHA MOTORS Seminar(SKYLINE)

CRITERIA ADOPTED FOR

VENDOR ALLOCATION

There is a separate department for Purchase, where the

buyers buy the parts from the vendors on regular basis
The task of analyzing, revising and settling price with the
vendors is borne by Purchase Planning department.
Workload balance between each group and each
buyer within a group
Part experience of each buyer
Sheet metal and fabrication parts divided in 3 groups
Proprietary parts divided in 2 groups
Electrical parts divided in 2 groups

Vendor allocation is an important task for purchase

Engineers.

YAMAHA MOTORS Seminar(SKYLINE)

production plan

PYMA
C
PAN YAMAHA MANUFACTURING CONTROL

YAMAHA MOTORS Seminar(SKYLINE)

All

YMC uses its own built Enterprise Resource Planning

Software known as PYMAC, which has been extended
to be used by all the subsidiary companies in various
countries, IYM being one of them. This is an MRP
system that connects YMC, Japan and its group
companies worldwide along with vendors.

For purchase planning dept., PYMAC allows to view database

related to:
CKD (Completely Knocked Down) exported bikes
COMMON calendar , job information etc.
DE (Design) - R&D related information, like BOM of a part,
MRP information of a part etc
IC (Inventory Control) inventory information.
PP (Production Planning)- production information.
VICS (Vehicle Information Control System)

YAMAHA MOTORS Seminar(SKYLINE)

Part no. allocation

Every part has a certain no. which denotes

the specification of the part and where to
use it
It is the part no. which allows us to call
where it is required, such as in revision of
price, requirement in production
department and many more things are
required
Its biggest advantage is in the field of
planning, record keeping, and analysis
while making any changes. In order to
represent any part its part number is
necessary.
All these things are mentioned by the part no itself.

YAMAHA MOTORS Seminar(SKYLINE)

How to allocate part no.?

Step 1: Identify the model in which the part is

being used and according to that first three letters
are allocated to it
STEP 2: The 3rd letter of the part no. represents the
section which the part belong to E= engine, F=
body, H=electric symBOL
STEP 3: Now next terms represents the drawing no.
such as 4121 etc.
STEP 4: End suffix represents the location of the
stores 80,m1,m2.
MODEL
SECTION
21CE471000080
DRAWING

LOCATION

YAMAHA MOTORS Seminar(SKYLINE)

There are five pymac cards

Pymac cards

The pymac cards are necessary for the functioning of

pymac. These cards help us to enter data to
pymac.
There are 5 pymac cards
Receipt card:-this is an acknowledgement of thje
delivery of the material. This card will be provided
to vendor.
Inspection card:-this is the card for QA judgment
(OK/NG). Further this is indicator of inspection for
vendor item
Item card:-This will be used same like movement
tag.

YAMAHA MOTORS Seminar(SKYLINE)

Delivery slip:-this will be issued to vendor at the

time of MRP run for 15 days. This slip will be
scanned at the time of the receipt of material will
subsequently will update the stocks on real time.
Complete report card:-this will be used when the
production is complete for the desired order no.
and has to be entered in system.

MADE BY:YAMAN SINGH

ROLL NO:0715340116
ME B 4RT YEAR.