Traceability Inventory

Transmission Traceability & Shipment ControlMr. Peter Itoa, IT Manager, GETRAG FORD Trasmissions Slovakia, s.r.o.

Logistic Conference 2015Bratislava, March 18, 2015

Agenda

1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction

2. Business Requirements

3. Project Definition

4. Technical Overview

5. Deliverables

2

Agenda





5. Deliverables

3

Key Figures

FormationFebruary 1, 2001 as 50:50 joint venture of GETRAG and Ford of Europe

Development and productionof transmissions

HeadquartersCologne

Production plantsCologne

Halewood

Bordeaux

Kechnec

GETRAG FORD Transmissions

44

Sales

1.16 billion

World Production

1.5 million transmissions

Employees

4,400

Full Service Systems Supplier

5

Our service range covers the entire process chain:

including all engineering services and spare parts

Idea Concept PrototypingVehicle

integration

Mass

productionValidation

GETRAG FORD Transmissions

GETRAG worldwide

March 23, 2015Company Presentation6

24 locations worldwide in Europe, North America and Asia

14 individual companies

Key Facts 2013

March 23, 2015Company Presentation

GETRAG in figures

3.2 Billion EUR 3.9 Million transmissions

Sales Global production Employees

7

13,250

Plant Kechnec

8

Production of dual clutch transmissions

(GETRAG PowerShift)

Established

2005

mid 2007 (start of mass production)

Employees

1000

Built capacity

265k units / year

- planned extension 400k

GETRAG FORD Transmissions Slovakia s.r.o.

Site Management

Wes Jacklin

Kechnec

Key features:

Torque Range up to 450 Nm

2 variants:

MPS6 (3 shaft design)

for C- and CD-car

SPS6 (short 2x2 shaft design)

for CD-car and SUV

AWD capable

Products: Powershift Transmissions 6DCT450

9

Agenda





5. Deliverables

10

Agenda


2. Business requirements

3. Project definition


5. Deliverables

11

Problem #1 - TRACEABILITY

Powershift: 37 500 m2

LSC: 10 152 m2

Problem #2 - QUALITY

Business Issues ...Why has been project established?

Insufficient quality control tracking of built transmissions

Missing posibility of unique tracking of each produced piece

Only transmission type & quantity

Inventory inaccuracy

Undesired stock-taking differences

Negative influence of human factor

The main objective

Prevent the export of any transmission that can have a quality problem

Inventory accuracy

IT system supporting "STOP SHIPMENT" process

Precise control of each produced piece

Identify & track the causes that led to the eventual qualitative deficiency

Minimum production and logistics downtime for initial serialization of inventory at GoLive

Business Need = Project Goals

Agenda





5. Deliverables

17

Agenda





5. Deliverables

18

Requestor

Plant TOP Management

Project Sponsor

Senior Manager Manufacturing Engineering

Project Leader

Local Plant IT employee

Business processes overview

IT expertise

Project leadership potential

Project Name

Transmission Shipment Control (TSC)

Project Management Methodology

PRINCE2TM

19

TOP

DOWN

Project Definition & Potencial

Kechnec team:Projekt leader: 1person (IT)

Logistics: 3 persons

Production: 1 person

Quality: 2 persons

Engineering: 2 persons

Local IT: 2 persons

Central IT: 1 person

Suppliers:HP

Quantum

Project Team

Project Steering Committee: Kechnec Plant

GETRAG Central IT

HP

Quantum

Project timing

1 year (November 2011 December 2012)

Project set up with

German HP consultants/ developers working remotely

Team from Quantum Information Systems Solutions Inc.

Local Slovak customer team (Business and IT)

Regular status audios and web-based workshops were held to ensure the quality of

the deliverables

During Go-live the entire team worked onsite in the Kechnec plant to

support the initial serialization of the complete transmission inventory

ensure a smooth go live of all new functions

Delivery approach

Agenda





5. Deliverables

22

Agenda





5. Deliverables

23

Available IT Landscape

Assembly End of Line Testing Repair/Repack/Garage Logistics storages Shipping

S/N HU+

TS

C

inte

rfa

ces

1

2

3

5 4

6ATC

inte

rfac

e

-Net -Net

Before Now

Derivate A

Derivate B

As

sy->

EO

L->

Ware

ho

use->

Sh

ipp

ing

->C

usto

mer

Serial #

Batch

processingUnique

Identification

&

blocking

The productive SAP ERP ECC 6.0 functionality has been enhanced by implementation of:

serial number & handling unit management

warehouse management for shipping stock

New SAP processes for Logistics have been designed in order to easily: handle stock transfers

picking

labeling

loading using radio-frequency scanner devices

The existing interface between Q-Net and SAP has been reengineered and new

scenarios have been developed in order to support: automatic confirmations

stock transfers

packing

reflash

quality blocks

Delivery approach (2) (technical view)

Agenda





5. Deliverables

28

Agenda





5. Deliverables

29

TSC Solution Highlights

Full traceability

Unique identification of each single transmission in SAP and Q-Net based on serial number

No SAP movement of transmission without identification by serial number

Controlled quality status of each unique transmission

No shipment of NOK/Blocked transmission

Minimum manual data input

Hand Held Scanners data input & Automatic data exchange to reduce human failure

Agility

Flexible system configuration to easily allow enhancements and roll-outs

Full flow control of each single transmission

from ASSEMBLY to the TRUCK

TSC Practical Deliverables & Business Benefits

Blocking process

Improved, speeded up and related to single serial number

Increase of transmission stock accuracy

0 inventory difference during 2012&2013 annual physical inventory

Transmission Warehouse Management

Immediate transmission localization in LSC

Enhanced transmission picking and shipment

FIFO

Transmission twins discovering

Success Stories of Kechnec TSC Solution

32

HP NEWSLETTER: Success Story in GETRAG

Transmission Shipment Control in SAP ECC 6.0 and Q-Net

TSC roll-out in GETRAG Mexico

Irapuato plant, Base on Kechnec pilot, GoLive: 07/2014

TSC roll-out in GETRAG Germany

Neunstein plant , GoLive: 12/2014

Thank you for your attention

Traceability Inventory

Documents

Transcript of Traceability Inventory