KAMAZ can win in the value chain by using PearlChain, an open model company that provides real-time engineering databases and supply chain management tools. PearlChain's concepts help synchronize production and logistics through sequencing of material availability, production status, and logistics information. This allows calculation of coverage levels and full trailer loads to optimize just-in-time delivery from suppliers to production lines. NedCar automotive plant uses PearlChain to achieve continuous three-shift production of 1200 cars per day with high availability and fault tolerance.

1. Why KAMAZ can Win
in the Value Chain

2. PearlChain: The real-time open
model company

3. Agenda
Engineering Database
Pearlchain Concept
SupplyCockpit
Coverage/Level Calculation
Full Trailer Load
Trailer Yard Control
SupplyCockpit Screens
SupplyCockpit Database

4. Slide 4
The Automotive Supply Chain
80% added value 20% added value
Supply Chain Management (external processing)
Enterprise border
ERP:
(internal processing) Interfaces
n tier 2 tier 1 tier OEM
supplier supplier supplier
Logistic Flow
PearlChain - concept

5. Slide 5
NedCar in a nutshell
• The process is completed in four sequential phases :
Press Shop Body Shop Paint Shop Final Assembly
• NedCar produces 200.000 top quality cars / year or
1000 cars / day or 1 / minute.
• 25% of all the industrial robots in the Netherlands are used by NedCar
• Each robot needs control Cell Control

6. MAN: Truck range
MAN TGL: MAN TGM: MAN TGA:
True class from 7.5 Mid-range power from High performance
to 12 tonnes 12 to 26 tonnes from 18 to 50 tonnes
Special-purpose Military vehicles
vehicles
6

7. Slide 7
Spotlight on NedCar
Pearlchain In
Planning / Ordering / MRP & Production horizon and how they relate

8. Slide 8
Technical Requirements
• Continuous three shift operation
• 1200 Cars produced every day
• One car every 52 seconds
• 20 Control points in the production flow
• 2500 Items and 200 work instructions per car
• 10.000.000 New database records per day
• 200 Suppliers receiving more then 50.000
messages daily
High availability
Fault tolerance
Platform independence
Scalability
Performance

9. Slide 9
From Manufacturing Execution System to
Management Information System
Apollo Core Production Systems
Web Server
Production PI Computer
BS-online PS-online
(op vakantie)
Integrated
Manufacturing Execution System Computer
BS-DXV BS-MGX PS FA-DXV FA-MGX
WBS PBS
Web server
TS SE
Computer
Web Browser
PLC-Scada

10. Flow Based Logistics concept: Pearlchain
Synchronisation of production and logistics
material
view in
sequence
PearlChain
sequence
production WOW
view in
sequence
keep keep keep sequence
restore restore delivery
sequence sequence
BODYSHOP PAINTSHOP FINAL ASSEMBLY

12. Slide 12
Lean at Porsche
The Porsche production system is simple
Principles
•Pull principle
•Takt principle
•Flow principle
•Zero-defect principle

13. Pearlchain, production progress and supply control
supplier A
supplier B
supplier C
supplier D
MATERIAL FLOW
material avail. material on traileryard material shipped material
for production to be shipped
NedCar
NedCar supplier A
lineside pull dock
pull

14. Slide 14
Engineering db – Inac / Shape-it
Idea
Product Process
FMC Logistics
Product Process
VCC Logistics
Multi Partner
Developme
KDP
KDP
Engineering KDP
KDP
Process KDP
xx
Authorized flows, Packaging
nt
format definitions
Material Addresses
Parts, Change Order
Prod Def Features,
PII
Production
Concept
Multi Plant
Engineering Database
Plants
Order
OS MO T&T MD
Product
Production

15. Slide 15

16. Slide 16
Important Condition Relations ( in
INAC)
Logical Expression : <attribute><operation><value> Atomic Condition
=
Logical Expression : <attribute> <operation> = ‘=‘, value =
= ‘TRUE’
Logical Expression : ‘(‘ logical expression ‘)’ Nesting
=
Logical Expression : Logical expression + logical AND
= Expression
Logical Expression : Logical Expression ‘/’ logical OR
= expression
Logical Expression : - Logical Expression NOT
=
1. UPG Mirror = Heated Mirror  Lux Level = ‘ High’ (Attribute = Lux Level, Value = High)
2. UPG Mirror = Heated Mirror  Heated Mirror (Attribute = Heated Mirror, Value = True)
3. UPG Mirror = Heated Mirror  ‘Lux Level’ = ‘High’ / Heated Mirror
4. UPG Mirror = Heated Mirror  (‘Lux Level’ = ‘High’ + Market = ‘Japan’) / Heated Mirror
5. UPG Mirror = Not Heated Mirror  - Heated Mirror

17. Logistics Strategy
From warehouse stock towards Warehouse On Wheels
Recent New
internal warehouse stock Warehouse On Wheels

18. Flow Based Concepts
SILS JIS JIT
• well known but … • Flow based, sequence • Flow based, batch
• Delivery in real (GC) • 2 h accuracy level • 2 h accuracy level
sequence • Coverage calculations • Coverage calculations
• Delivery under • Full Truck Load Calc. • Full Truck Load Calc.
responsibility of • Delivery based on • Delivery based on
supplier planned sequence planned sequence
• Meanly for modules • Warehouse on Wheels • Warehouse on Wheels
production flow
actual Supplier
realised Material available
Warehouse on wheels Material shipped Material to be shipped
production for production
Available op traileryard DELFOR / AVIEXP
processed

19. Process flow

20. Calculation coveragepointers algorithm
PARTCLUSTER_LEVEL
RPS APS RPY APY RPU APU HighestWU
PCH-in PBS-off WU MP GOK
…. ….
ALU= 80
ALY= 60 RLU= 100
ALS=40 RLY= 85
PEARLS
RLS= 65
PCH sequence Realisation
PART_COVERAGE
Previous
last WH
PCH-in SPF SPS SPY SPU PBS-off WU MP GOK
…. ….
LSF= 55 LSS= 40 LSY= 55 LSU= 100
QUANTITY
PCH sequence Realisation
coverage calculation

21. Pearlchain monitor (order and
body early alert)
Square:Order
Circle: Body

22. Coverage Timebucket Screen (1)

23. Coverage Timebucket Screen (2)

24. Full Trailerload for JIT algorithm
PBS-off
E.G. JIT PARTCLUSTER 1 : PART 1, 2, 3 TRAILERCODE =10 QUANTIY = 9
PCH-in
Package part 1 Package part 1 Package part 1 COV. PART 1
UN+YA+SH+FI
PCH-in
Package part 2 Package part 2 Package part 2
COV. PART 2
UN+YA+SH
PCH-in +FI
Package
Package part 3 Package part 3
part 3 COV. PART 3
UN+YA+SH
+FI
T12 T11 T10 T9 T8 T7 T6 T5 T4 T3 T2 T1
FULL TRAILERLOAD FOR PARTCLUSTER (9 COLLI)

25. Trailer-flow
KanBan call-off by OEM
Supplier
Location: FIRM to Supplier
Call-off status: ‘ ’
DesAdv by Supplier
to OEM
Location: OFF YARD
Call-off status: ‘ ’
Location: SHIPPED
Confirm trailer
Call-off status: ‘ ’
off yard
Automatic Call-off
Confirm trailer
by coverage-alg.
on Yard
Confirm trailer
off dock
Location: UNLOADED
Location: OFF DOCK
Location: YARD Call-off status: Empty
Call-off status: ‘ ’
Call-off status: ‘ ’
Confirm
Call-off trailer
empty trailer
on Yard
Location: YARD Location: YARD Location: UNLOADED
Call-off status: Called - off Call-off status: T-Master Call-off status: On Dock
Select Confirm
trailer by trailer On
T-master Dock

26. View PearlChain (2)

27. View EDI-messages
Events Message types
FP : Final Pearlchain release RS : Resend SP : Syncro Planned
QC : Quick Change MC: Manual Communication SC : Syncro Call off
DP : Delete pearl UN : Unloaded KC : Kanban Call off
RP : Refreshed pearl FI : Firm
UF : Unfirm
MT : Manual trailer

28. NedCar Workingcapitalinvestment in material
VX/DX 2003 Volume
KD Pearlchain benefits
1,1 M
0,9 M Value/Modules
6,0 M
WOW
1,6 M Stock reduction
24,3 M
6,9 M
NCC 2005
7,9 M

29. Thank you for your attention
Rudy Hageman
Rudy.Hageman@PearlChain.net
0032 473 88 33 30
PearlChain.net
Roderveldlaan 2
2600 Berchem
Belgium