barcamp 12 mei 2011 - pearl chain
TRANSCRIPT
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
Slide 4
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
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: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
Slide 7
Pearlchain In
Planning / Ordering / MRP & Production horizon and how they relate
Spotlight on NedCar
Slide 8
• 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
Slide 9
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
Slide 14
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
Slide 15
Slide 16
Logical Expression :=
<attribute><operation><value> Atomic Condition
Logical Expression :=
<attribute> <operation> = ‘=‘, value = ‘TRUE’
Logical Expression :=
‘(‘ logical expression ‘)’ Nesting
Logical Expression :=
Logical expression + logical Expression
AND
Logical Expression :=
Logical Expression ‘/’ logical expression
OR
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 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
Call-off status: ‘ ’
Confirm trailer
off dock
Confirm
empty trailer
Supplier
Location: SHIPPED
Call-off status: ‘ ’
Location: FIRM
Call-off status: ‘ ’
Automatic Call-off
by coverage-alg.
DesAdv by Supplier
to OEM
KanBan call-off by OEM
to Supplier
Location: OFF YARD
Call-off status: ‘ ’
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
0032 473 88 33 30