福特汽车物料规划与运筹.ppt

1,Fordlio-HoMaterialPlanningAndLogistics福特六和物料規劃與運籌,MP&LManagerA.L.Fan范阿浪協理,2,FordProductionSystemandVision,MP&LMission,RoleandResponsibilityofMP&LModelLine-UpComplexityProductionScheduleandReleaseMP&LExteriorandInternalLogisticsCommonMaterialManagementSystem,IntroductionofFLHMP&L介紹內容,3,何謂福特生產系統(FPS)?,福特生產系統(FordProductionSystem)FPS是一精實(lean)及一致的生產系統，經由整合後勤供應系統，支持FPS的目標，促使Ford所有的生產工廠內皆能排除物料、空間、設備及時間等浪費。,4,精實(lean)，有彈性(flexible)，紀律性(disciplined)有能力及被授權的員工。共同學習並安全的工作在一起。持續性的提供超越顧客在品質、成本及時效上的期望。,福特生產系統願景(FPSVision),5,FPS精實(Lean)生產的5個階段性步驟,1,穩定性生產(製程自我改善),2,流動連續生產(製程自我改善),同步化生產(協力廠商的配合),3,拉動式系統(協力廠商的配合),4,平準化生產(整合營銷與協力廠商),5,穩定之作業製程能力，有一致性之生產流程,作業站與站之間單件流的連續生產,穩定與一致性的作業流程，包括物料之同步化供應,穩定一致的作業站，拉動式之物料供應，完全符合作業站需要,依據顧客訂單生產，生產量及配比完全平準化,6,福特生產系統的執行,福特產品開發系統FPDS,售後服務.Sales&Services.QualityCare.CustomerSatisfaction.GQRS,從訂單到交車(OrdertoDelivery),福特生產系統FPS6Sigma/VCATS/TQE,C,M,I,D,C,D,A,P,A,7,執行,預測,計劃,生產排程,供應商排程,BOM,存貨管理,福特六和汽車,供應商,顧客,出貨,運送管理,驗收,訂單及發料,供應商需求,生產排程,檢料包裝,生產,存貨,存貨資料,出貨排程,顧客需求,ASN,支援的流程管理資源工程設變品質工具教育訓練資訊控制,規劃,資訊流,物料流,運輸,供應鍊圖,供應商排程,8,Coststructure成本結構,9,MissionOfMaterialPlanningandLogistic物料規劃與運籌之使命,Tooptimizetheglobalsupplychainthrough:Synchronousflowofinformation.Synchronousflowofmaterial.Coordinationoftheoverallprocessofproduction.,10,MP&LRoleandResponsibility物料規劃與運籌之角色與責任,11,MP&LMetrics物料規劃與運籌之衡量指數,12,Pre-Productionpreparation,ProductionScheduling&Release,ImportPartsSupplyChainManagement,InventoryControl,LocalPartsSupplyChainManagement,MajorFunctionOfMaterialPlanningandLogistics物料規劃之組織與功能,13,ModellineandComplexity生產車型及物料一覽表,14,OtherMajorComplexity其他主要複雜度,DifferentPartNumberingSystemPartscountnear10,000(9,986)EngineeringChangeControlSystemClaimandPSPO(MPPO)SystemsLessPartsCommonization,休旅車,轎車,商用車,15,FLHMPL-ExteriorLogistics(Import)進口零件運籌概況圖,JapanSuzukiPronto,FordLoHoPlant,USIEOU204/J1414Directshipparts3.0Engine2.0/3.0T/M,RGL,MexicoChihuahuaEng.2.0,Coughlin,JapanMazadaC206EIIU204,JapanJatco2.5AutoT/M,EuropeIEOCD132,Huppertz,HBuildingCD132,PXPWeeklyShipmentTransitTime51Days(Including16DaysFloat)i,PXPWeeklyShipmentTransitTime10Days,PXPWeeklyShipmentTransitTime46Days,LotWeeklyShipmentTransitTime10Days,16,FLHLocalComponentsLogistics台灣本地零件概況,North:62suppliersDeliveryTime:1-1.5H,MajorComponents:StampingParts/TrimParts/Seat/Tire/ChassisParts/ColorParts,Middle:12SuppliersDeliveryTime:34H,South:11SuppliersDeliveryTime:5-6H,TotalQ1Suppliers:85,MajorComponents:Hand-onParts/Wiring/Lamp/Pistonetc.,MajorComponents:DoorTrim/ParkingCable/Glass/Topceilingpistonpinetc.,17,FLHBOM/MaterialmanagementSystem零件表之管理,Sourcechangecontrol.Spec./usageclarification.BOMMaintenance.Obsolescencecontrol.Productfeaturechange,18,OrdertoDelivery從接訂單到交車,19,生產計劃與訂料,A月的20日在生產計劃會議上決定A+1月的需求,生產計劃的考量因素零件情況工廠產能車型車種之平均與平準,以CMMS3發出交貨通知單45天的計劃12個月的預估量,每日生產報告,為CD132發出單一零件A+4月的交貨通知單,批購CKD1.A+3月2.A+4月15%及A+5月20%的變動量,進口零件到廠,監控A+3月的船期,監控進口零件的庫存量及倉儲遲滯費用的發生,與各工廠主任討論生產計劃,生產計劃與本地零件的訂購,進口零件的訂購,20,MaterialRequirementReleasingProcessforSpecialVehicleOrdersfromDealers特別訂單車的物料作業程序,Illustration:EverySVOisbuiltonabasemodelAddedanddeletedpartlistisderivedfromthebasemodelTheNumbers:Jan:305Feb:137Mar:45Apr:111May:205Jun:73Total:876units,ReleaseoftheNormalProductionPartsoftheBaseModel,ReleaseoftheAddedPartstotheBaseModel,21,Release交貨單的產生,FordProductsCD132(VehicleLineCNE),WERS,CMMS,WIPS,SOLMIS,Supplier,NON-FordProductsMazda,SuzukiandFordMazdaU204,ImportParts:,KDLotOrderByMSC.Lot,KDSource,LocalParts:,TESS(Manual),CMMS,WIPS,SOLMIS,Supplier,22,FLHVendorReleasesystem物料交貨通知系統,Forecast45DaysDailyRequirement12MonthsForecastrequirementOrderLineUpDealerOrder(FromSIDOBank)tobeMaintained14Days,VIS,EmergingMktsSch.ProcessGPAMSolve,NiehlCologne,Germany,CMMS3FloatTransittime%ofBusinessOthers,VenderReleaseDaily(862)LocalWeekly(830)Local&Import3MonthsWeekly3MonthsMonthly,23,KDLotOrdering&SupplyTimingFrame(Japan)批量訂購與供應時間,FirmOrderForMonthA+2PackingForMonthA+3Production,PackingForThe1StShipment,PartsOnTheSea,CustomsClearance,1StShipmentIN-PlantForProduction,24,1stOceanFreightRoute,APL,SystemSetUpforEuropeanLogistics單件訂購之時間設定,25,(2),(6),(1),(3),(4),Totalmeasureofarea:341,650squaremeter,26,FLHVehicleInformationSystem車輛資訊系統,VehicleInformationSystem,Supplier,Body,Paint,FAP-1,FAP-2,Warehouse,Dealer,Shipping,CAI,Final,PBS,OnTrim,CAI,Allocation,Primer,27,FLHVendorDeliveryPattern台灣本地零件交貨方式,1.ILVSDelivery:Seat,Tire,SideSkirt,Bumper,DoorTrimPanel.(SynchronizeddeliverybasedonOn-LineInformationBroadcastSystembyPBS).2.KanBanDelivery:BodyParts,LargeScaleParts.3.GeneralMRPDelivery.,28,In-plant&Out-plantSequentialFeeding(ILVS)廠內廠外序列交貨方式,Supplier,MarketArea(574parts),PBS,PBSpasstheproductionsequenceinformationtothePickingstationTheoperatorpicksthepartsaccordingtoproductionsequenceandputinthetrolleyinsequenceTheoperatordeliverthepartswithtrolleytothefitofpoint,(1),(2),(3),Benefits:Tosavelinesidespaceandreduceoperatorworkloadhandlingpartscomplexity,(Out-plant:324parts),29,ColorPartsDeliveryProcess顏色零件之交貨程序,BodyAllocation,FordLioHo,Suppliers,Send1+6BodyAllocationat3:30PM,Email,Multifrequencydeliverybaseonon-to-primerinformationILVSdeliveryforBumper,sideskirt,30,SMARTOffice,ZoneMailbox,Kan-BanPartProcess看板供料程序,SerialNumber,LinesideMailbox,LinesideMailbox,OperatorA,OperatorB,WorkgroupLeader,MH,Benefits:Tokeeplinesideinventoryataminimumlevel,improve5Sandreduceemergencydelivery1.Theoperatorpicksthekan-banattachedinthecontainerwhenheusesthefirstpieceofthepart.2.Theworkgroupleadercollectsthekan-baninLinesideMailboxesandsendsthemtoZoneMailboxeverythreehours.3.MHcollectsthekan-baninZoneMailboxesandsendsthemtoSMARTOfficeforsortingandputtingthemindifferentMarketMailbox.4.Thenumberofthekan-bansentbacktoMarketMailboxarethenumberofcontainerstobedeliveredtothelineside,LineFeederB,MarketArea(764parts),LineFeederA,MarketMailboxA,MarketMailboxA,7:20AM,7:30AM,7:40AM,31,CallPartsProcess呼叫供料,Calllightboard,ABC,A,B,C,B,Callbutton,MarketArea(269parts),Benefits:Tominimizestocklevelsatlinesideandspareoutspacesforthenewpartsofnewmodel.Theoperatorpushesthecallbuttontorequestthepartheneeds.ThelightonthecalllightboardforthepartwillbefleshingindicatingtheparthasbeingrequestedThelinefeederpushestheresetbuttonontheResetpanelresetThelinefeedcometomarketareatopickthepartanddelivertothefitofpoint,(1),(2),(4),Callbutton,Callbutton,Total:269parts,32,InventoryControlProcess庫存管理程序,PackSizeConfirmation,FloatDayParameterSet-upinCMMS,WeeklyOn-SiteReview,InventoryObjectiveSet-up,InventoryPerformanceReview,ContinuousImprovement,Form-1121Confirmation.,ByEachAnalyst,MonthlyinventoryPerformancereviewbyEachAnalyst,FollowupActionPlan,SafetyStock/Adv.JobShippingFrequency,OrgReviewTeam,33,MaterialControl物料管理,福特生產系統小組活動倡導每一位員工對物料的新觀念以合乎同步物流的要求防止刮傷人人有責紅桌物料檢討物料改善會議庫存檢討改善會議門禁,34,ModelB/outManagementprocess車種結束物料管理程序,DiscontinuePartsList,FirstCycleCount,SecondCycleCount,SpecialCycleCount,Analystsubmitthelists,SpecialcountforLocal-importparts3monthsbeforebalanceoutAdjustBOH.,SpecialCountonemonthbeforeBalanceoutAdjustBOH.,SpecialCountbyMSC,35,MS-9000物料管理系統簡介,MS-9000物料管理系統為福特汽車事業總部根據ISO-9000及QS-9000之精神所發展出來的物料管理系統及評估標準，為最高的物料規劃標準。評分方法：評分依20要項，每一要項再依O、M、C及CI（4）個層級問題來評定，分別給予每一要項03分再以要項的平均分數乘以50來計算，總分範圍為0150分。基本要求條件：最低必要條件新廠商80分以上，且各項問題評分不得低於1分。Q1獎必要條件最低100分，且各項問題評分不可低於2分。TQE獎必要條件符合Q1必要條件及通過TQE審核。,36,MS-9000物料管理系統必要條件,4.1管理責任4.2物料管理系統4.3檢討合約/客戶接觸面4.4時間表系統4.5文件控制4.6採購轉包商管理4.8產品驗證與追蹤4.9裝船4.10製告彈性/存貨管理4.11檢驗測量與測試,4.14糾正與防範4.15處理、存放、包裝和交貨4.15.2處理4.15.3存放4.15.4包裝4.15.6交貨4.16物料記錄的與控制4.17物料內部審核4.18訓練4.20統計方法,37,SupplierDeliveryPerformance協力廠商交貨實績,CriteriaASNAchievement:30%Timeliness:20%ShippingDiscrepancy:20%Overshipment:5%Packaging:15%ProblemReport:10%,38,執行SixSigma的現況,2000年開始推廣SixSigma黑帶訓練開始2001年計畫開始上課並執行2002現況:黑帶人數:2人執行專案5個綠黑人數:53人執行專案14個節省金額:U$2,000/專案,39,通用物流管理系統,40,進口零件來源，訂購及包裝方式,JapanSuzukiPronto,USIEOU204/J1414Directshipparts3.0Engine2.0/3.0T/M,MexicoChihuahuaEng.2.0,JapanMazadaC206EIIU204,JapanJatco2.5AutoT/M,EuropeIEOCD132,Huppertz,HBuildingCD132,RGL,Coughlin,PXPWeeklyShipmentTransitTime51Days(Including16DaysFloat)i,PXPWeeklyShipmentTransitTime46Days,LotWeeklyShipmentTransitTime10Days,PXPWeeklyShipmentTransitTime10Days,FordLoHoPlant,41,PartByPart訂購(Metrostar),批量訂購(其他車種Mazda,SuzukiandFordU204),以車型車種別以批量訂購KDLotOrderByMSC.Lot,國外供應商KDSource,全球工程發行系統WERS,通用物流管理系統CMMS,供應商資訊系統SOLMIS,供應商,訂單發送方式,42,BridgeInterfaceBetweenCorporate&LocalSystem,CMMS3-CD132PartUsage-VBOM,WIPS,ATP,Sourcing,SOLMIS,TradingCompany,USSupplier,Mailbox,FLHLocalSupplier,Release(CIF830/862),ASN(CIF856),VIS,Mailbox,EuropeanSystem-MSCEOCSFI,EXCELFileDaily/MonthlyVehicleSchedule,CatCodetoEOC,Forecast/Offline/OrderLine-up,AccountsPayable,Mailbox,Receipt(1-32),ActualPrice,ApprovedToolingData,Receipt,ActualPrice,ApprovedToolingData,PANDA,Mailbox,UnitCost,FAPC,CommittedToolingData,ICSImportpartspricemark-up,PriceLook-up,PriceLook-up,Mailbox,MultipleBridges,ImportParts,CMMS3ASN(web-based),VehicleCostAccounting,MQSeries,Sourcing,MSCtoSFIConversion,Mailbox,Mailbox,Mailbox,EuropeanSupplier,43,TaiwanForecast/SchedulingFeedstoCMMS3,TAIWANLOCALSYSTEM(VIS),CatCode/EOCTableKDLot,EmergingMktsForecastProcess,EmergingMktsSchedulingProcess-GPAMSolve,CumCounts,CMMS3,CatCodeToEOCFile,CatCodeToEOC,CatCodeForecastByPeriod,Segmented/SequencedOrderLine-upEOC,Day0Prod(Offline)Body&AssyplusCaptiveSeq.OrderLine-upEOC,SFICountsTYDProdDay-1,(Bridge3-43),SFI,EOC,Day0Offline&CaptiveSeq,ConfirmedOrderLine-up,GPAMTable,OpPlanforTaiwan,EventTableforTaiwan,MaterialForecastSFIbyday,EventTableOpPlan,(Bridge3-43),(Bridge3-42),(Bridge3-44),EXCELFILE=Daily&MonthlyVehicleSchedule,44,批量(LotKit)訂購與PartByPart訂購與包裝,最低包裝量最低訂購量,45,(CommonMaterialManagementSystem)主要功能產生物料清單及單一零件採購功能以支援所有物流作業。推展零件製造計劃,生產排程及安全存貨計劃。計算及發佈每日/每週的交貨通知給供應商。提供即時的存貨狀態和資料驗證。管理各儲存區的物流進/出轉移作業。以條碼系統收集零件使用量。出貨程序的管理。計算交易及存貨價值並提供存貨預算的控制報表。提供與供應商及顧客間的電訊雙向溝通。,通用物流管理系統(CMMS),46,系統設置及導入,由福特歐洲製程先導部門主導總投資費用：US$1,697,000