wms (warehouse management systems · wms -sils centers 17 nov 2005 page 11 • eds internal sils in...
TRANSCRIPT
03-23-0517 Nov 2005
WMS (Warehouse Management SystemsWMS (Warehouse Management Systems))
SILS Centers . Process requirements and market solutions
Presented by Chema Guallar
WMS - SILS Centers 17 Nov 2005
AgendaAgenda
• JIT/SILS
• Describe SILS base concepts
• Historical facts
• … and when the SILS arrives
– Supply Chain
– Messages
– Material flow
– Timing
– Tasks
• SILS – System overview
– Basic operations
• IT Market solutions
• Case study - ILPA
WMS - SILS Centers 17 Nov 2005
JIT / SILS (I)JIT / SILS (I)
• “Just In Time”
– Deliver under “pull concept”
• Andon
• Two cycles replenishment
– Batch delivery
• Kanban
• Minimum stock level
• Full container movements
– Solves constant delivery flow in “trains”
– Minimize stock space needed in-line
– Reduce pressure to supplier
WMS - SILS Centers 17 Nov 2005
JIT / SILS (II)JIT / SILS (II)
• “Suply In Line Sequence”
– Delivery under individual order
• Under assembly sequence
• Discrete production
– Sub-assembly
– Kit preparation
• Strict window delivery time
– Deliver under lot/bin control
• Small lot size (around 20 units)
• Individual units of work
– Minimum space on-line needed
– Quality assurance in advance
• No time to reject/rework
WMS - SILS Centers 17 Nov 2005
JIT / SILS (III)JIT / SILS (III)
• Powerful IT systems required to support:
– Radically different organizational criteria
– Strong functional constraints
• Short delivery-time
• No chance to re-work parts
• Close to delivery point
• Deal with transportation
– Quality assurance before sequencing starts
– Strict & precise stock control
• Deep view in order live
• Custom container/rack
WMS - SILS Centers 17 Nov 2005
SILS SILS –– base conceptsbase concepts
• Order
– Each set of units of work to be delivered with distinctive information, i.e. by car
• Point-of-use
– OEM Area in which materials must be delivered
• Sequence
– Strict list of order in the way they need to be accomplished, sorted by time, and point-of-use
• Materials
– List of parts to be delivered in sequence; specifically informed by order
• Time-window
– Amount of time available for the supplier to provide the materials at point-of-use since proper sequence signal has been released by the OEM for an specific order.
WMS - SILS Centers 17 Nov 2005
SILS SILS -- Historical factsHistorical facts
• Suppliers at near or medium distance OEM plant
• Big stock on-line and off-line to avoid:
– Interruptions : really expensive
– Rework : produces Qualitative defects
– Delivery issues –delays- : Customer satisfaction.
•Warehouses inside OEM near production line
• Two Cycles replenishment
– Kanban
– Lean (visual) management
– Inventory task implies extra shifts/costs
page 8 • EDS InternalWMS - SILS Centers 17 Nov 2005
Warehouses in classic Supply ChainWarehouses in classic Supply Chain
InternalWarehouses
InternalWarehouses
OEM
Supplier Resp.
Sequencing
Sub-assembly
Replenishment
Sequenced
Product
PUS
DELFOR
TIER 1
TIER 1
WMS - SILS Centers 17 Nov 2005
• Stock warehaouse
– Maintains main stock (2 or three days)
– Big space wasted
• Intermediate Warehouse
– Keep the material needed in the point-of-use in the next hour/s
– Dense forklift traffic
• Point-of use
– Replenished using Kanban technique
StockWarehouse
Empty binsWarehouse
Point-of-use
Cycle 1Cycle 2
Material Flow
Empty bins flow
IntermediateWarehouse
Two Cycles replenishmentTwo Cycles replenishmentTwo Cycles replenishment
WMS - SILS Centers 17 Nov 2005
…… and when the SILS arrivesand when the SILS arrives
• small number of majormajor suppliers located
–– Really closerReally closer : SILS pure model
– Medium distance : Two stages SILS, mixed JITmixed JIT--SILSSILS
– Long Range : Pre-assembly in SILS delivery in JIT
• Very few stock on-line
– Only security stocksecurity stock for more frequent parts
– SILS supplier presence inpresence in--plantplant
• No or very rare storage areas inside OEM
•• continuouscontinuous replenishment
– Sequenced bin or trolleys
– Contents list to help visual control
page 11 • EDS InternalWMS - SILS Centers 17 Nov 2005
SILS in Supply ChainSILS in Supply Chain
SILS CenterSILS Center
OEM
TIER 1
DELFOR
PUS
Sequenced
Product
Sequencing Schedule
Production Schedule
ASN
Payment on
Consumption
TIER1
To reduce costs and increase flexibility, there will be very little storage within the supply chain. The implications for suppliers are that production must move away from batch systems towards flexible single piece systems with very short cycle times. They must have control of their suppliers so that continued supply can be assured, and quality systems must be integral with manufacturing so that inspection of deliveries is not required
WMS - SILS Centers 17 Nov 2005
TIER 1supplier
Delivery Forecast EDIFACT DELFORDaily Ship Schedule EDIFACT DELJIT SH
ASN (EDIFACT DESADV)
AOR ( Acknowledgement of receipt) (EDIFACT RECADV)
SILSsupplier
EDIFACTSynchroDELJIT
SILS messages flowSILS messages flow
OEM
Call-Off
Pre-Info
Paymentpoint
WMS - SILS Centers 17 Nov 2005
supplier
Differentsites
ShippingControl
PartRackPoURoute
sub-assembly/sequencing
line supply
empty depotsequence rackssupplier
empties
suppliermaterial receipt/control/handlingof empties
intermidiatestorage
subassemblysequencing
preparation/loading Zaragoza
shuttletransport
linesupply
shelf/ rackstorage
block storage
receiving
Requirements Planned
SILS material flowSILS material flow
OEM
WMS - SILS Centers 17 Nov 2005
SILS Centre. Process timing sequencingSILS Centre. Process timing sequencing
15.5 min 12 min 10 min 5 min 10 min 10 min 15.4 min
Window time 78 min
• unloading• curtain
transport-ation(15 km/ h1.1 km)
• allocation• check out• loading• curtain
line feeding(full racks +empties)
signalrelease(batch of12 cars)
bufferapprox. 12 cars
Assembling
Pa ckmi ttel N r 10 0
P 0 511 0
Ch arge n Nr
Ku nde/ Werk Ab lade stelle /Lag eror t
3A 88 9 X X0 LH KJ 11 0
Lie fera nt
Ge wich t ne tto br utto S tck
Ku nde/ Werk
Ve rsan ddat um
sequencing(separate for
each line)
sub-assembling
WMS - SILS Centers 17 Nov 2005
• Material receipt
• Material control
• Intermediate storage of materials
• Retrieval and management of:• sequence• kitted material,• sub-assembling• replenishment material
• Sub-assembling
• Sequencing
• Shuttle transportation to the OEM plant
SILS Centers. Suppliers mall tasks SILS Centers. Suppliers mall tasks
supplier 1
SILS center
• unloading
• curtain
• line feeding
• Management of emptiestrucking
truckingsupplier 2
supplier 3
supplier n
page 16 • EDS InternalWMS - SILS Centers 17 Nov 2005
SILS SILS -- System OverviewSystem Overview
EDI
ORDERS
DELIVERY
PICKING
PACKING
BIN HANDLING
LOADING
RECEIVING
STORAGE &
RETRIEVAL
SHIPMENT
SEQUENCINGSEQUENCING
page 17 • EDS InternalWMS - SILS Centers 17 Nov 2005
SILS at Supplier side SILS at Supplier side -- Basic OperationsBasic Operations
RF Terminals
forklifts
Storage & Retrieval
Retrieval & Replenishmentorder
Picking & Packing
Order processing
Orders & Materials
RF Terminals
Pickers
HOST
(Sequencing Signals)
CompletionStatus
Move order
AS/AR
Facility
Shipping
Goods In
Pick order
Receiving
Ship order
Goods Out
Storageorder
Label Printers
WMS - SILS Centers 17 Nov 2005
Containers
Empty containers
Reset Button
Indicator Light
Optical sensor
Field Bus
Remote I/O
controller
PN 9999991 PN 9999992 PN 9999993 PN 9999994
SILS SILS -- Picking & error proofing Picking & error proofing –– Concept exampleConcept example
PickingIndicator
PickingControl
PartCheck
OrderReleased
page 19 • EDS InternalWMS - SILS Centers 17 Nov 2005
SILS at OEM SILS at OEM -- Basic OperationsBasic Operations
RF Terminals
forklifts
Point-of-Use
Retrieval & Replenishmentorder
OEM base product
Route planning
Orders & Materials
Electronic tags
Production Planning
Assembly
Shipping
Sequenced Parts in racks
Assembly order
Unloading &receiving
Goods Out
Delivery sequence
Label Printers
WMS - SILS Centers 17 Nov 2005
SILS SILS –– Delivery point Delivery point -- Concept OverviewConcept Overview
SILS Center
OEM Plant
Hand-over
point
TIER 1
WMS - SILS Centers 17 Nov 2005
• Performance required
– connectivity
– Logic & control
– Real time operations
• Different vendors/customer products
– As standalone
– As add-ons to WMS COTS
– Bespoke solutions
• SILO example
IT Market solutionsIT Market solutions
WMS - SILS Centers 17 Nov 2005
Performance required (I):Performance required (I):
• Must support different formats
– VDA 4912-13-16,
– EDIFACT SYNCHRO DELJIT
– Others (non estándar OEMs)
• And different networks
– TCP/IP,
– X.25
– RS-232/485
WMS - SILS Centers 17 Nov 2005
Performance required (II):Performance required (II):
• Logical control
– On-line events flow.
• Messages control
– Against Master Database.
• Sequence validation:
– Warning on skips, duplicates,
– User advice
– Non correlated sequence tools.
WMS - SILS Centers 17 Nov 2005
Performance required (III):Performance required (III):
• Order maintenance.
– Real time
• Historical records
– Trace and tracking of server materials
– Events managment, simulation
• Quality assurance
– Block incoming goods
– Inspections
– Rejections on-line
WMS - SILS Centers 17 Nov 2005
Different vendors/customer productsDifferent vendors/customer products
• Vendors involved in standard packages are focusing on JIT solutions more than SILS
– SAP
– BPCS
– Movex
• Vendors delivering IT solutions to automotive industry –the remarkable leader in SILS usage- have deep knowledge on SILS
– ALTA
– EXE
– Gedas
– EDS
• Some customers decides to create their own solution
– Bertone
– VOLVO
• Others selects market solutions
– OPEL
– Delphi
– Wolkswagen
WMS - SILS Centers 17 Nov 2005
Case study
ILPA
SILS CentreSequencing Serviceof Production Parts
WMS - SILS Centers 17 Nov 2005
Basic DataBasic Data
incoming goods: approx. 74 trucks per day1,373 container per day ���� 3,800 cbm
production: 1,950 cars per day 92 cars per hour 2 assembly lines ���� 46 cars per line/ hour
line feeding: approx. 2,090 sequence racks per dayurgent modules: Ø 12 parts per racknon urgent modules: Ø 24 parts per rack
sequencing: 15 modules (355 variants)
sub assembling: 5 modules (56 variants)
generals: 220 working days / 3 shifts
WMS - SILS Centers 17 Nov 2005
PremisesPremises
Inventory range: 3 - 5 days
ABC: 20 / 80 % rule20 % of the articles of each module make up 80 % of the volume of thatmodule
Location capacity: actual value target capacity
Block 2426 2050 85 %
Racking 4700 3884 83 %
WMS - SILS Centers 17 Nov 2005
material receiving/ dispatch: 2,350 sqm
storage: 8,050 sqm
sequencing / sub-assembling 3,800 sqm
QS/ blocked deliveries area: 200 sqm
traffic area (general) 3,600 sqm
total 18,000 sqm
Dimensions and spaceDimensions and space
Warehouse Dimensions:Length 180 mWidth 100 m
WMS - SILS Centers 17 Nov 2005
Receiving / DispatchReceiving / Dispatch
Service
• truck unloading / loading
• temporary storage in receiving area
• receiving delivery notes
• producing internal SILS-labels
(tracking and tracing)
• scanning, booking
• counter check against the dispatch
advice from the supplier
• rejecting wrong parts, oversupply
• quality / quantity checks
(goods inwards inspection)
• storage area: 2,350 m²
Rec
eivi
ng
550
m² Des
patc
h A
rea
Em
ptie
s
600
m²
200
m²
Facility LayoutFacility Layout
WMS - SILS Centers 17 Nov 2005
Block StorageBlock Storage
Service:
• block storage for stackable goods
• block storage for oversized packaging
• A-item with a high inventory range
(high replacement time)
• storage area: 2,750 m²
V a r ia n te 1
V a r ia n c e 1V a r ia n c e 1
V a r ia n c e 1V a r ia n c e 2
V a r ia n c e 1V a r ia n c e 3
V a r ia n c e 1V a r ia n c e 4
V a r ia n c e 1
V a r ia n te 1V a r ia n c e 2
V a r ia n te 1V a r ia n c e 3
412
E m p ti e s
V 5V 6V 7
V 8V 9V 1 0
V 1 1V 1 2V 1 3
V 1 4V 1 5V 1 6
E m p tie s
Blo
ck Sto
rage
2750 m²
Facility LayoutFacility Layout
WMS - SILS Centers 17 Nov 2005
RackingRacking
Service:
• rack storage for non stackable goods
• rack storage for standard packaging
• B and C-items with a lower inventory
range (lower replacement time)
• storage area: 2,300 m²
• storage capacity: 4,700 locations
1,2
m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m2
,6 m
2,6
m
1,8
m
1,2
m
1,2
m
1,8
m
1,2
m
1,2
m
1,8
m
1,2
m
1,2
m
1,8
m
1,2
m
1,2
m
1,8
m
1,2
m
1,2
m
1,8
m
1,2
m
1,2
m
4700
Lo
cati
on
2300
m²
2,6
m2
,6 m
2,6
m
1,8
m
1,2
m
Facility LayoutFacility Layout
WMS - SILS Centers 17 Nov 2005
Sequencing / Sub-assemblingSequencing / Sub-assemblingService:
• random access to every part
• replenishing material
• preparation for picking, 100% check to
guarantee that correct part is in correct
package (sample board)
• sequence picking, 100% cross check with
the BCC (Broadcast Code)
• minimum inventory check: visual
• FIFO
• Sub-assembling
• sequencing area: 3,200 m²
• sub-assembling area: 600 m²
13
9
V 4
124
13
55
42
1213
113
8
Picking
Replenishing
Picking
Picking
Picking
Picking
7
Replenishing
Replenishing
Replenishing
V 14V 15V 16
V 8 Variance 1
2200 m²
1,2 m
Facility LayoutFacility Layout
WMS - SILS Centers 17 Nov 2005
Facility LayoutFacility Layout
100 m
Variante 1
10
116
14
Office
QS
Desp
atchA
rea
180 m
Variance 1Variance 1
Variance 1Variance 2
Variance 1Variance 3
Variance 1Variance 4
Variance 1
Variante 1Variance 2
Variante 1Variance 3Variance 2
Variance 1
Variance 2
Variance 3
412
13
9
Empties
V 6V 7
V 4V 4V 5 Variance 2
Variance 3
ILP
AIL
PA
ILP
A
V 5V 6V 7
V 8V 9V 10
V 11V 12V 13
V 14V 15V 16
V 11V 12
V 9V 10
V 8 Variance 1Variance 1
I-Point
Em
pties
Battery
Blo
ckedM
aterial
9
Empties
600 m²
200 m²
124
13
55
42
1213
1
38
Picking
Replenishing
Picking
Picking
Picking
Picking
7
Replenishing
Replenishing
Replenishing
2200 m²
Receivin
g550 m
²
Blo
ck Sto
rage
2750 m²
550 m²
60 m²
75 m²
160 m²
80 m²
120 m²
60 m²
1,2 m
2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m 2,6 m
1,8 m
1,2 m
1,2 m
1,8 m
1,2 m
1,2 m
1,8 m
1,2 m
1,2 m
1,8 m
1,2 m
1,2 m
1,8 m
1,2 m
1,2 m
1,8 m
1,2 m
1,2 m
4700 Location2300 m²
2,6 m 2,6 m 2,6 m
1,8 m
1,2 m
15
WMS - SILS Centers 17 Nov 2005
Process planning and conceptProcess planning and concept
Pa ckmi ttel N r 10 0
P 0 511 0
Ch arge n Nr
Ku nde/ Werk Ab lade stelle /Lag eror t
3A 88 9 X X0 LH KJ 11 0
Lie fera nt
Ge wich t ne tto br utto S tck
Ku nde/ Werk
Ve rsan ddat um
min
30 60 120 180 240
65 min minimum window time 78 min.
WMS - SILS Centers 17 Nov 2005
Door - Line Cockpit -Line
receiving
Line FeedingLine Feeding
WMS - SILS Centers 17 Nov 2005
ProductionPLC Network
Middleware
Production & Logistic Control
Production Line PP & PROVIDERS
SILO/Lite(Unix/Oracle)
SILS IT SILS IT –– Architecture (SILO example)Architecture (SILO example)
PLC 0
PLC 2
PLC n
PLC MASTER
TCP/IP
PLC Conveyor
ProductionPlanning
TCP/IP
Providers
RF
RF
RF
RF
RF
Edifact
Reception.
Quality Assurance
Shipping.
Internal Movement
TCP/IP
Operationalworkplaces
ISO 802.11
Edifact / Odette
SILO-Auto
SILO-SILS/MES
SILO-E
DI
SILO-Wireless
WMS - SILS Centers 17 Nov 2005
EmergencyEmergency issuesissues
incoming goods inspection
FIFO - principle
packaging development support
inventory level control
permanent physical inventory
maintenance agreements (contracts)
✔
✔
✔
✔
✔
✔
WMS - SILS Centers 17 Nov 2005
mobile communications technology
altern. communication channel via fax
IT hardware redundancy
flexible working time model
possibility to insist on professional and specialised personnel
✔
✔
✔
✔
✔
EmergencyEmergency issuesissues
03-23-0517 Nov 2005
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