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Logistieke Barcamp 12 mei 2011 - Pearl chain

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Logistieke Barcamp 12 mei 2011 - Pearl chain

  1. 1. Why KAMAZ can Win in the Value Chain
  2. 2. PearlChain: The real-time open model company
  3. 3. Agenda Engineering Database Pearlchain Concept SupplyCockpit Coverage/Level Calculation Full Trailer Load Trailer Yard Control SupplyCockpit Screens SupplyCockpit Database
  4. 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. 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. 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. 7. Slide 7 Spotlight on NedCar Pearlchain In Planning / Ordering / MRP & Production horizon and how they relate
  8. 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. 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. 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
  11. 11. Slide 12 Lean at Porsche The Porsche production system is simple Principles •Pull principle •Takt principle •Flow principle •Zero-defect principle
  12. 12. 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
  13. 13. 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
  14. 14. Slide 15
  15. 15. 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
  16. 16. Logistics Strategy From warehouse stock towards Warehouse On Wheels Recent New internal warehouse stock Warehouse On Wheels
  17. 17. 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
  18. 18. Process flow
  19. 19. 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
  20. 20. Pearlchain monitor (order and body early alert) Square:Order Circle: Body
  21. 21. Coverage Timebucket Screen (1)
  22. 22. Coverage Timebucket Screen (2)
  23. 23. 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)
  24. 24. 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
  25. 25. View PearlChain (2)
  26. 26. 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
  27. 27. 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
  28. 28. Thank you for your attention Rudy Hageman Rudy.Hageman@PearlChain.net 0032 473 88 33 30 PearlChain.net Roderveldlaan 2 2600 Berchem Belgium

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