特料规划与运筹.

1、1 Ford lio-Ho Material Planning And Logistics 2 nFord Production System and Vision, nMP&L Mission, Role and Responsibility of MP&L nModel Line-Up Complexity nProduction Schedule and Release nMP&L Exterior and Internal Logistics nCommon Material Management System Introduction of FLH MP&L 介紹內容 3 何謂XXX

2、X生產系統(FPS)? XXXX生產系統(Ford Production System) 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 n有能力及被授權的員工。 n共同學習並安全的工作在一起。 n持續性的提供超越顧客在品質、成本及 時效上的期望。 XXXX生產系統願景(FPS Vision) 5 1穩定性生產穩定性生產 ( (製程自我改善製程自我改善) ) 2流動連續生產流動連續生產( (製程自我改善製程自我改善) ) 同步化生產同步化生產( (協力廠商的配合協力廠商的配合) )

3、3 拉動式系統拉動式系統( (協力廠商的配合協力廠商的配合) )4 平準化生產平準化生產 ( (整合營銷與協力廠商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 符合作業站需要符合作業站需要 依據顧客訂單生產，生產量及配比完全平依據顧客訂單生產，生產量及配比完全平 準化準化 6 XXXX生產系統的執行 X

4、XXX產品開發系統 FPDS 售後服務 .Sales & Services .Quality Care .Customer Satisfaction .GQRS 從訂單到交車 (Order to Delivery)XXXX生產系統 FPS 6Sigma /VCATS / TQE CM I D C DA P A 7 執行 預測 計劃 生產排程 供應商排程 BOM 存貨管理 XXXX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

5、物料流 運輸 供應商排程 8 Cost structure 成本結構 MaterialVar. MarketingLabor O/H DutyFix MarketingTooling Others 9 Mission Of Material Planning and Logistic 物料規劃與運籌之使命 To optimize the global supply chain through: n Synchronous flow of information. n Synchronous flow of material. n Coordination of the overall proc

6、ess of production . 10 MP&L Role and Responsibility 物料規劃與運籌之角色與責任 Synchronous Material Flow Synchronous Information Flow Optimized Supply Chain Right Material Stable and Accurate information flow Minimal Inventory Right Quality Data formal enables transformation from data to knowledge to predictabil

7、ity Minimal Expending Right PackingMinimal Lead- time Right LocationRight TimeOptimized Logistic Right TimeLowest Total Cost 11 MP&L Metrics 物料規劃與運籌之衡量指數 Build to Schedule Dock to Dock OEE Number of Parts On Pull Replenishment Inventory Turn Build to order IM Fill Rate Total Cost Conveyances On Wind

8、ow 12 Pre-Production preparation Production Scheduling & Release Import Parts Supply Chain Management Inventory Control In-Plant Material Handling Local Parts Supply Chain Management 物料規劃之組織與功能物料規劃之組織與功能 13 Model line and Complexity 生產車型及物料一覽表 Item Model Cat Code MSC SourcePack Pack SizeImpor t Part

9、s Item Local Parts Item No of Consign ment Parts ModelCommonSatellite 1 C206 Tierra 18MazdaLot NB LI18080 720101019 LIII12080 J396020 HB6040 2 C224MA V Premacy 4MazdaLot Ford C224 6040 702 109061 Mazda J54 40 3 CD 132 Mondeo 16EuropePXP PXP From Europe. Engine from Chihuahua, T/M from Batavia 863875

10、56 4 U204 Escape 8 US IEOPXP Direct Sourced from US 14 parts 770595149 MCLot6020 5EII 8MCLot4090081821 6Pronto10SuzukiLot4879784668 Total6447525234374 14 Other Major Complexity 其他主要複雜度 Different Part Numbering System Parts count near 10,000 (9,986) Engineering Change Control System Claim and PSPO (M

11、PPO) Systems Less Parts Commonization 15 FLH MPL-Exterior Logistics (Import) 進口零件運籌概況圖 Japan Suzuki Pronto Ford Lo Ho Plant US IEO U204/J14 14 Direct ship parts 3.0 Engine 2.0/3.0 T/M RGL Mexico Chihuahua Eng. 2.0 Coughlin Japan Mazada C206 EII U204 Japan Jatco 2.5 Auto T/M Europe IEO CD132 Huppertz

12、 H Building CD132 PXP Weekly Shipment Transit Time 51 Days (Including 16 Days Float)i PXP Weekly Shipment Transit Time 10 Days PXP Weekly Shipment Transit Time 46 Days Lot Weekly Shipment Transit Time 10 Days 16 新竹縣 澎湖群島 高雄縣 屏東縣 台東縣 台南縣 嘉義縣 台北縣及基隆市 花蓮縣 南投縣 雲林縣 彰化縣 台中縣 苗栗縣 宜蘭縣 桃園縣 蘭嶼 綠島 新竹 基隆 台北 台中 嘉

13、義 台南 高雄 台東 花蓮 FLH Local Components Logistics 台灣本地零件概況 North: 62 suppliers Delivery Time: 1-1.5H Major Components : Stamping Parts/Trim Parts/Seat/Tire/ Chassis Parts/Color Parts Middle : 12 Suppliers Delivery Time: 34H South : 11 Suppliers Delivery Time: 5-6H Total Q1 Suppliers : 85 Major Components

14、: Hand-on Parts/Wiring /Lamp/Piston etc. Major Components: Door Trim/Parking Cable /Glass/Top ceiling piston pin etc. 17 FLH BOM/ Material management System 零件表之管理 WERS/TES S Engineering Release Engineering BOM Manufacturing BOM Establishment & maintenance Engineering Change control and management n

15、 ECN n Notice KD Local CMMS3 M | BOM nTPCR nDeviation Source change control. Spec. /usage clarification. BOM Maintenance. Obsolescence control. Product feature change 18 Order to Delivery 從接訂單到交車 19 生產計劃與訂料 A A月的月的20 20 日在日在 生產計劃會議上決生產計劃會議上決 定定A+1A+1月的需求月的需求 生產計劃的考量因素生產計劃的考量因素 零件情況零件情況 工廠產能工廠產能 1.車型

16、車種之平均與平準車型車種之平均與平準 以以CMMS3 CMMS3 發出發出 交貨通知單交貨通知單 4545天的天的計劃計劃 1. 12個月的預估量個月的預估量 每日生產報告每日生產報告 為為CD132CD132發出發出 單一單一零件零件A+4A+4月的月的 交貨通知單交貨通知單 批購批購CKDCKD 1.A+31.A+3月月 2.A+42.A+4月月15 %15 %及及 A+5A+5月月20%20%的變動量的變動量 進口零件到廠進口零件到廠 監控監控A+3A+3月月 的船期的船期 監控進口零件的監控進口零件的 庫存量及倉儲遲滯庫存量及倉儲遲滯 費用的發生費用的發生 與各工廠主任與各工廠主任 討

17、論生產計劃討論生產計劃 生產計劃與本生產計劃與本 地零件的訂購地零件的訂購 進口進口零件零件 的訂購的訂購 20 Material Requirement Releasing Process for Special Vehicle Orders from Dealers 特別訂單車的物料作業程序 Illustration: Every SVO is built on a base model Added and deleted part list is derived from the base model The Numbers: Jan : 305 Feb: 137 Mar: 45 Apr

18、: 111 May: 205 Jun: 73 1.Total: 876 units Release of the Normal Production Parts of the Base Model Release of the Added Parts to the Base Model 21 Release 交貨單的產生 Ford Products CD132 ( Vehicle Line CNE ) WERSCMMS WIPS SOLMISSupplier NON-Ford Products Mazda, Suzuki and Ford Mazda U204 KD Lot Order By

19、MSC. Lot KD Source TESS (Manual) CMMS WIPS SOLMIS Supplier 22 FLH Vendor Release system 物料交貨通知系統 Forecast 45 Days Daily Requirement 12 Months Forecast requirement Order Line Up Dealer Order (From SIDO Bank) to be Maintained 14 Days VIS Emerging Mkts Sch.Process GPAM Solve,Niehl Cologne, Germany CMMS

20、3 Float Transit time % of Business Others Vender Release Daily (862) Local Weekly (830) Local & Import 3 Months Weekly 3 Months Monthly 23 KD Lot Ordering & Supply Timing Frame (Japan) 批量訂購與供應時間 AA+1A+2A+3A+4 Firm Order For Month A+2 Packing For Month A+3 Production Packing For The 1 St Shipment Par

21、ts On The Sea Customs Clearance 1St Shipment IN-Plant For Production 24 123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051 parts leave trading company custom clearence & in-plant, 3 days ready for production 16 days float Transit time 35 days Remarks: Syste

22、m set-up We set up total 51days as the parameter of in-transit time for supplier release calculation in CMMS3. The 51 days in-transit time includes: 1. Vessel shipping on water: 27 days 2. Trading Company to Port: 5 days 3. Custom & Clearance : 3 days 4. Safety Float Stocks : 16 days Release lead ti

23、me prior to production 1. In compliance with rules indicated in IEO supply manual, a 3-week lead time is required for fabrication at suppliers. Furthermore, another week of part delivery and packing is needed. 2. Combining all the lead time, including transit time, part fabricartion, delivery, and p

24、acking, part requirements for production in a specific week should be firmed 74 days in advance. Vessels leave Rotterdam But FLH parts not loaded Vessels leave Rotterdam Vessels leave Felixstowe Leave Antwerpen Vessel leave Southampton APL K Line 2nd Ocean Freight Route, K Line 5 Days 27 Days 1st Oc

25、ean Freight Route, APL System Set Up for European Logistics 單件訂購之時間設定 25 (2) (6) (1) (3) (4) Total measure of area: 341,650 square meter 26 FLH Vehicle Information System 車輛資訊系統 Vehicle Information System Supplier Body Paint FAP-1 FAP-2 Warehouse Dealer Shipping CAI Final PBS On Trim CAI Allocation

26、Primer 27 FLH Vendor Delivery Pattern 台灣本地零件交貨方式 1. ILVS Delivery: Seat, Tire, Side Skirt, Bumper, Door Trim Panel. (Synchronized delivery based on On-Line Information Broadcast System by PBS). 2. Kan Ban Delivery: Body Parts, Large Scale Parts. 3. General MRP Delivery. 28 In-plant & Out-plant Seque

27、ntial Feeding (ILVS) 廠內廠外序列交貨方式 Supplier A A A A B B Market Area (574 parts) CC C CD D F F F E CC C CD D A A A A B B F F F E PBS PBS pass the production sequence information to the Picking station The operator picks the parts according to production sequence and put in the trolley in sequence The op

28、erator deliver the parts with trolley to the fit of point (1) A A A A B B (2) (3) Benefits: To save line side space and reduce operator workload handling parts complexity (Out-plant: 324 parts) 29 Color Parts Delivery Process 顏色零件之交貨程序 Body Allocation Ford Lio Ho Suppliers Send 1+6 Body Allocation a

29、t 3:30 PM E mail Multi frequency delivery base on on-to-primer information ILVS delivery for Bumper, side skirt 30 SMART Office A A A A B B F F F E CC C C D D Fill Active Fill Active Fill Active A-01A-03 AA AAAA AAA AAA BBCC B B BBB BBB DDD DDD CCC CCC Part CPart BPart APart D DD Zone Mailbox Kan-Ba

30、n Part Process 看板供料程序看板供料程序 Serial Number Lineside Mailbox Lineside Mailbox Operator A Operator B Workgroup Leader MH Benefits: To keep line side inventory at a minimum level, improve 5S and reduce emergency delivery 1. The operator picks the kan-ban attached in the container when he uses the first

31、piece of the part. 2. The workgroup leader collects the kan-ban in Line side Mailboxes and sends them to Zone Mailbox every three hours. 3. MH collects the kan-ban in Zone Mailboxes and sends them to SMART Office for sorting and putting them in different Market Mailbox. 4. The number of the kan-ban

32、sent back to Market Mailbox are the number of containers to be delivered to the line side Line Feeder B Market Area (764 parts) Line Feeder AMarket Mailbox A Market Mailbox A 7:20 AM 7:30 AM 7:40 AM 31 Call Parts Process 呼叫供料 Part Number SMART No Market Address Line Side Address F7C6-5422401-AG 0001

33、22 DTL-A-02 E26-N-010 F8C6-5426075-AA 005126 DTL-A-03 E27-S-020 F7C6-5467934-AB 003412 DTL-A-01 E26-N-030 Call light board A B C A B C B Call button Market Area (269 parts) Benefits: To minimize stock levels at line side and spare out spaces for the new parts of new model. The operator pushes the ca

34、ll button to request the part he needs. The light on the call light board for the part will be fleshing indicating the part has being requested The line feeder pushes the reset button on the Reset panel reset 1. The linefeed come to market area to pick the part and deliver to the fit of point (1) (2

35、) OnOff OnOff OnOff A B C Reset panel (3) (4) Call button Call button Total: 269 parts 32 Inventory Control Process 庫存管理程序 Pack Size Confirmation Float Day Parameter Set-up in CMMS Weekly On- Site Review Inventory Objective Set-up Inventory Performance Review Continuous Improvement Form-1121 Confirm

36、ation. By Each Analyst Monthly inventory Performance review by Each Analyst Follow up Action Plan Safety Stock/Adv.Job Shipping Frequency Org Review Team 33 Material Control 物料管理物料管理 nXXXX生產系統小組活動生產系統小組活動 n倡導每一位員工對物料的新觀念以合乎同步物倡導每一位員工對物料的新觀念以合乎同步物 流的要求流的要求 n防止刮傷人人有責防止刮傷人人有責 n紅桌物料檢討紅桌物料檢討 n物料改善會議物料改善會

37、議 n庫存檢討改善會議庫存檢討改善會議 n門禁門禁 34 Model B/out Management process 車種結束物料管理程序 Discontinue Parts List First Cycle Count Second Cycle Count Special Cycle Count Analyst submit the lists Special count for Local- import parts 3 months before balance out Adjust BOH. Special Count one month before Balance out Adj

38、ust BOH. Special Count by MSC 35 MS-9000MS-9000 物料管理系統簡介物料管理系統簡介 nMS-9000 物料管理系統為XXXX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。 n評分方法：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。 n基本要求條件基本要求條件： n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。 nQ1獎必要條件最低100分，且各項問

39、題評分不可低 於2分。 nTQE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 Supplier De

40、livery Performance 協力廠商交貨實績 nASN Achievement:30% nTimeliness:20% nShipping Discrepancy:20% nOver shipment:5% nPackaging: 15% 1.Problem Report:10% 38 執行Six Sigma 的現況 n2000年開始推廣Six Sigma黑帶訓練開 始 n2001年計畫開始上課並執行 n2002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 40 Japan Suzuki Pronto US IEO U20

41、4/J14 14 Direct ship parts 3.0 Engine 2.0/3.0 T/M Mexico Chihuahua Eng. 2.0 Japan Mazada C206 EII U204 Japan Jatco 2.5 Auto T/M Europe IEO CD132 Huppert z H Building CD132 RGL Coughlin PXP Weekly Shipment Transit Time 51 Days (Including 16 Days Float)i PXP Weekly Shipment Transit Time 46 Days Lot We

42、ekly Shipment Transit Time 10 Days PXP Weekly Shipment Transit Time 10 Days Ford Lo Ho Plant 41 以車型車種別以批量訂購以車型車種別以批量訂購 KD Lot Order By MSC. Lot 國外供應商國外供應商 KD Source 全球工程發全球工程發 行系統行系統 WERS 通用物流管通用物流管 理系統理系統 CMMS 供應商資訊系統供應商資訊系統 SOLMIS 供應商供應商 訂單發送方式 42 Bridge Interface Between Corporate & Local System

43、New Module To Be Developed Corporate System Existing Local System CMMS3 - CD132 Part Usage - VBOM WIPS ATPSourcing SOLMIS Trading Company US Supplier Mailbox FLH Local Supplier Release (CIF830/862) ASN (CIF856) VISMailbox European System - MSC EOCSFI EXCEL File Daily/Monthly Vehicle Schedule CatCode

44、 to EOC Forecast/ Offline/ Order Line-up Accounts Payable Mailbox Receipt (1-32) Actual Price Approved Tooling Data Receipt Actual Price Approved Tooling Data PANDA Mailbox Unit Cost FAPC Committed Tooling Data ICS Import parts price mark-up Price Look-up Price Look-up Mailbox Multiple Bridges Impor

45、t Parts CMMS3 ASN (web-based) Vehicle Cost Accounting MQ Series Sourcing MSC to SFI Conversion Mailbox Mailbox Mailbox European Supplier 43 Taiwan Forecast/Scheduling Feeds to CMMS3 TAIWAN LOCAL SYSTEM (VIS) CatCode/EOC Table KD Lot Emerging Mkts Forecast Process Emerging Mkts Scheduling Process - G

46、PAM Solve Cum Counts CMMS3 CatCode To EOC File CatCode To EOC CatCode Forecast By Period Segmented/ Sequenced Order Line-up EOC Day 0Prod (Offline) Body & Assy plus Captive Seq. Order Line-upEOC SFI Counts TYD Prod Day-1 (Bridge 3-43) SFI EOC Day 0 Offline & Captive Seq Confirmed Order Line-up GPAM

47、Table Op Plan for Taiwan Event Table for Taiwan Material Forecast SFI by day Event Table Op Plan (Bridge 3-43) (Bridge 3-42) (Bridge 3-44) EXCEL FILE = Daily & Monthly Vehicle Schedule 44 批量(Lot Kit) 訂購與 Part By Part 訂購與包裝 Parts Usage/ Pack12345 A 4 B 1 C 5 D 3 E 2 Parts Pack123456789101112 A 6 B 12 C 7 D 5 E10 45 (Common Material Management System) n產生物料清單及單一零件採購功能以支援所有物 流作業。 n推展零件製造計劃,生產排程及安全存貨計劃。 n計算及發佈每日/每週的交貨通知給供應商。 n提供即時的存貨狀態和資料驗證。 n管理各儲存區的物流進/出轉移作業。 n以條碼系統收集零件使用量。 n出貨程序的管理。 n計算交易及存貨價值並提供存貨預算的控制報表。 n提供與供應商及顧客間的電訊雙向溝通。 通用物流管