Logistieke Barcamp 12 mei 2011 - Pearl chain

Why KAMAZ can Winin the Value Chain

PearlChain: The real-time openmodel company

Agenda

Engineering Database

Pearlchain Concept

SupplyCockpit

Coverage/Level Calculation

Full Trailer Load

Trailer Yard Control

SupplyCockpit Screens

SupplyCockpit Database

The Automotive Supply Chain

OEM1 tiersupplier

n tiersupplier

2 tiersupplier

ERP:(internal processing)

Supply Chain Management (external processing)

Enterprise border

Logistic Flow

80% added value 20% added value

Interfaces

PearlChain - concept

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:True class from 7.5 to 12 tonnes

� MAN TGM:Mid-range power from 12 to 26 tonnes

� MAN TGA:High performance from 18 to 50 tonnes

� Military vehicles� Special-purpose vehicles

Pearlchain In

Planning / Ordering / MRP & Production horizon and how they relate

Spotlight on NedCar

• 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

Technical Requirements

PLC-Scada

Apollo Core Production Systems

Integrated Manufacturing Execution System

FA-DXVBS-DXV

TS

BS-online PS-online

Production PI

BS-MGX

WBS

PS

PBS

SE

FA-MGX

Web server

Web Server

FA-DXVBS-DXV

TS

BS-online PS-online

Production PI

BS-MGX

WBS

PS

PBS

SE

FA-MGXComputerComputer

Web Browser

ComputerComputer

ComputerComputer

From Manufacturing Execution System to Management Information System

(op vakantie)

Flow Based Logistics concept: PearlchainSynchronisation of production and logistics

PearlChain sequence

materialview insequence

productionview insequence

restore restorekeep sequence

keep sequence

keep sequence

BODYSHOP PAINTSHOP FINAL ASSEMBLY

delivery

WOW

Lean at PorscheSlide 12

Principles•Pull principle•Takt principle•Flow principle•Zero-defect principle

The Porsche production system is simple

Pearlchain, production progress and supply control

material avail. for production

material on traileryard material shipped material to be shipped

supplier A

NedCar

NedCardock

MATERIAL FLOW

pull

supplier Asupplier Bsupplier Csupplier D

lineside

pull

FMC LogisticsProcessProduct

Engineering Database

VCC

Developm

ent

Product Process Logistics

Production

KDPKDPEngineeringformat

KDPKDPProcess definitions

KDPxx

Prod D

ef Features,

Parts, C

hange Order

OrderOS MO

PII

T&T MD

Product

Material A

ddressesA

uthorized flows, P

ackaging

Idea

ProductionConcept

Plants

Multi Partner

Multi Plant

Engineering db – Inac / Shape-it

Logical Expression :=

<attribute><operation><value> Atomic Condition


<attribute> <operation> = ‘=‘, value = ‘TRUE’


‘(‘ logical expression ‘)’ Nesting


Logical expression + logical Expression

AND


Logical Expression ‘/’ logical expression

OR


- 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 Mirror4. UPG Mirror = Heated Mirror (‘Lux Level’ = ‘High’ + Market = ‘Japan’) / Heated Mirror5. UPG Mirror = Not Heated Mirror - Heated Mirror

Important Condition Relations ( in INAC)

Logistics StrategyFrom warehouse stock towards Warehouse On Wheels

Recent New

internal warehouse stock Warehouse On Wheels

Flow Based Concepts

SILS

• well known but …

• Delivery in real (GC) sequence

• Delivery under responsibility of supplier

• Meanly for modules

JIS

• Flow based, sequence

• 2 h accuracy level

• Coverage calculations

• Full Truck Load Calc.

• Delivery based on planned sequence

• Warehouse on Wheels

production flow

actualrealised

productionWarehouse on wheels

Material availablefor production Material shipped Material to be shipped

Supplier

Available op traileryard DELFOR / AVIEXPprocessed

JIT

• Flow based, batch

• 2 h accuracy level

• Coverage calculations

• Full Truck Load Calc.

• Delivery based on planned sequence

• Warehouse on Wheels

Process flowProcess flowProcess flowProcess flow

Calculation coveragepointers algorithm

PBS-offPCH-in

PCH sequence

….

WU MP GOK

Realisation

PBS-off

PCH sequence

….

coverage calculation

WU MP GOK

Realisation

PCH-in

PARTCLUSTER_LEVEL

PART_COVERAGE

PEARLS

….

RPYRPS APY RPU APUAPS

….

SPUSPS SPYSPF

LSU= 100LSF= 55 LSS= 40 LSY= 55

ALU= 80

HighestWU

RLU= 100 ALY= 60

RLY= 85

Previous last WH

ALS=40

RLS= 65

QUANTITY

Pearlchain monitor (order and body early alert)

Square:OrderCircle: Body

Coverage Timebucket Screen (1)

Coverage Timebucket Screen (2)

Full Trailerload for JIT algorithm

COV. PART 1

UN+YA+SH+FI

Package part 1Package part 1Package part 1

UN+YA+SH

+FI

Package part 2Package part 2Package part 2COV. PART 2

PCH-in

PCH-in

PBS-off

UN+YA+SH

+FI

Package part 3

Package

part 3Package part 3

COV. PART 3

PCH-in

T3 T2 T1T4T5T6T7T8T9T10T11T12

FULL TRAILERLOAD FOR PARTCLUSTER (9 COLLI)

E.G. JIT PARTCLUSTER 1 : PART 1, 2, 3 TRAILERCODE =10 QUANTIY = 9

Trailer-flow

Location: YARD

Call-off status: ‘ ’

Location: YARD

Call-off status: Called - off

Location: YARD

Call-off status: T-Master

Location: UNLOADED

Call-off status: On Dock

Confirm trailer

on Yard

Call-off trailer

on Yard

Select trailer by T-master

Confirm trailer On Dock

Location: UNLOADED

Call-off status: EmptyLocation: OFF DOCK


Confirm trailer

off dock

Confirm

empty trailer

Supplier

Location: SHIPPED


Location: FIRM


Automatic Call-off

by coverage-alg.

DesAdv by Supplier

to OEM

KanBan call-off by OEM

to Supplier

Location: OFF YARD


Confirm trailer

off yard

View PearlChain (2)

View EDI-messages

Events

FP : Final Pearlchain release

QC : Quick Change

DP : Delete pearl

RP : Refreshed pearl

RS : Resend

MC: Manual Communication

UN : Unloaded

FI : Firm

UF : Unfirm

MT : Manual trailer

Message types

SP : Syncro Planned

SC : Syncro Call off

KC : Kanban Call off

NedCar Workingcapitalinvestment in materialVX/DX 2003

24,3 M

Stock reduction

Volume

1,1 M KD

0,9 M Value/Modules

6,0 M

WOW

1,6 M

6,9 M

7,9 M

NCC 2005

Pearlchain benefits

Thank you for your attention

PearlChain.netRoderveldlaan 22600 BerchemBelgium

Rudy Hageman

[email protected]

0032 473 88 33 30

Logistieke Barcamp 12 mei 2011 - Pearl chain

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