Apresentação michael toth

SENAI International Workshop – Logistic

Impact of Material Flow Changes on the Sustainability of Global Supply Chains

Dr.-Ing. Michael TothFraunhofer IML

© Fraunhofer IML

The Fraunhofer-Society Locations in Germany

■ 60 Institutes

■ 18,000 employees

■ 1.8 billion Euro research volume■ 2/3 of this volume are generated with

orders from industry and with publicallyfinanced research projects.

■ 1/3 of it is contributed as basic funding by the federal and Länder governments

Institutes and facilities

Further locations

THE FRAUNHOFER IML

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The Fraunhofer IMLData and Facts

■ Founded in 1981■ More than 205 scientists, 200 student assistants■ 800 projects in a year■ Turnover of 22 million €■ Thereof 50% from industry, trade and services■ Branches and project centers in Frankfurt on Main, Prien on Chiemsee,

Hamburg■ Cooperation with HSG St. Gallen (Switzerland), Georgia Tech (USA),

Lisbon (Portugal), Shanghai (China), Rio de Janeiro (Brazil)

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The Fraunhofer IMLSelection of Latest Topics

PLANNING OF INTRALOGISTICS

WAREHOUSE MANAGEMENT

CELLULAR INTRALOGISTICS

SOFTWARE FOR INTRALOGISTICS

CONVERTIBLE LOGISTICS SYSTEMS

RFID APPLICATIONS

LOGISTICS MALL

MODELLING

SUPPLY CHAIN MANAGEMENT

FACTORY PLANNING

MAINTENANCE

LOGISTICS AS A SERVICE

LOGISTICS NETWORK

PLANNING OF LOCATION

GREEN LOGISTICS

MULTIMODAL LOGISTICS

AIR FREIGHT

MARITIME LOGISTICS

URBAN SUPPLY

DISTRIBUTION LOGISTICS

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Lab: openID-Center

■ 1500m² laboratory for industry and research

■ Showcase for all state-of-the-art-technologies in the supply chain

■ Integrated hard- and software from partners and sponsors

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■ Simulation of static, dynamic and climatic loads / forces on packaging systems

■ 400 m² of testing area and 6 employees

■ 60 to 80 projects per year

■ High tech testing equipment

■ 4 climatic chambers

■ 2 vertical vibration tables

■ 1 tension / compression test machine

■ 1 horizontal impact test system

■ 1 precision drop hook and table

■ 1 vertical shock test machine

Lab: Packaging Centre

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Logistics can no longer be Managed by the way

■ The days of being able to control logistics by intuition are over.

■ Logistics has become an interdisciplinary, highly complex discipline.

■ More than ever, logistics are called upon to contribute to issues of the future.

■ It is important to recognize logistics as technology and as a response to many social issues.

Creating tomorrow’s individuality with 75% of today’s resources.

Individuality Efficiency

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Key Issues for the Logistics of the Future

TransportationManagement

Environment and Sustainability

Urban Supply Logistics-as-a-Service

Design CompetenceReal-Time FlexibleLogistics Systems

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Sustainability in Logistics Networks

SocialSocial EconomicEconomic EcologicalEcological

Working conditions

Education and qualification

Ressourceefficiency Greenhouse gas

emissions

Noise emissions

Fair trade

Waste reduction

Land useRenewable

energy

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Focusing Only on Production Technology is Insufficient

High-value consumer and investment products are created in manufacturing networks.

High-value consumer and investment products are created in manufacturing networks.

Fields of action in holistic consideration of processes from the supplier to the consumer

Fields of action in holistic consideration of processes from the supplier to the consumer

Production technology and processes

Production boundaries:Efficient usage of

logistics resources

Transport Production 1 Transport Production 2 Transport Production n

2nd tier 1st tier OEM

Distribution

Store Provide-Valuecreation

1.1Pick Provide

Valuecreation

1.2

Valuecreation

1.nPackStore Pick

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Logistics Designs, Plans, and Executes the Production Environment…

Factory building and layoutFactory building and layout

Production and logistics facilitiesProduction and logistics facilities

Supply conceptSupply concept

Production networkProduction network

Logistics processesLogistics processes I&CI&C

Production organizationProduction organization

Halle 5

Halle 4

Halle 3/A

Halle6

Halle 7

Halle 1Halle

2

EM

EM

EM

VM

EM

EM

BSF

VM

VM/BSF

WA

WEGT

WA

VM

WEKTMaterialfluss

Informationsfluss

person

Zulieferer

LDL LDL

Produzent

Kunde

EntsorgerHandelProduct-Life-Chain

Materialfluss

Informationsfluss

person

Zulieferer

LDL LDL

Produzent

Kunde


MaterialflussMaterialfluss

InformationsflussInformationsfluss

person

Zulieferer

LDL LDL

Produzent

Kunde


Materialfluss

person

Zulieferer

LDL LDL

Produzent

Kunde


Materialfluss

Informationsfluss

person

Zulieferer

LDL LDL

Produzent

Kunde


DeploymentDeployment

JEE Application Server

ERP(e.g. SAP)

ERP(e.g. SAP)

JCA

Web Service(e.g. PI, OMNI)Web Service

(e.g. PI, OMNI)

Model Repository

Process Modelling

Model Repository

Process Modelling

Business Logic 2(EJB)




DesktopClient

DesktopClient

WebClientWeb

ClientMobileClient

MobileClient

DesktopClient

DesktopClient

WebClientWeb

ClientMobileClient

MobileClient

Business EventBusiness Event

Audit Trail Database

JDBC

EXP CARNOTProcess EngineEXP CARNOT

Process Engine

Audit Trail Database

JDBC

EXP CARNOTProcess EngineEXP CARNOT

Process Engine

JMSJMS

Messaging(e.g. Host)

Messaging(e.g. Host)

JCAJCA SOAPSOAP

Verpacken

Lagern

Kommiss-ionieren

...and determines its sustainability.

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Examples of the General Potential in Logistics Networks

Global Supply Chain■ Increase capacity usage through

bundling of transports■ Improved ratio of emissions over

transport performance■ Higher stock level required to absorb

peaks■ Less flexibility

■ Less express transports, e.g. air cargo■ Short lead times, low stock levels, but

high resource demand

Local Supply Chain■ New Supply Processes

■ Reduction of noise and gas emissions■ Resource Efficiency applying Lean

Concepts

■ Future Material Flow – Multishuttle

Perfor-mance

Costs Sustain-ability

Scope of decisionsPosition through

own decision

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Dynamics in Global Supply Chain Operations

Supply chain events and risks

Markets Demand dynamics Growth, Competition Forecast errors Sales promotions

Processes and resources Process quality Process stability Resource availability

Delayed vessels or air freight

Traffic

Transport delaysRework

Machine maintenance

OEMOEM Dealer / CustomerDealer /

Customer1st tier1st tier LSPLSPLSPLSP

Accidents

Staff unavailability

IT-breakdownMaterial defects

Machine breakdown

Capacity shortage

Quarantined customs goods

Supply shortage

Wrong delivery

StrikeTerrorism

Natural disasters

Supply chain performance Material quality Supplier performance Transports disruptions

Customers Order changes Adhoc orders Delivery date

modifications

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E²Log Project –Sustainability Through Energy Efficiency

Strategic Design

Strategic Design

Long-term Short-/medium-term

■ E²Log – Energy Efficiency in Logistics and Production■ Analysis of effects of decision in production on the energy efficiency

of the entire supply chain■ Integration of the objectives costs, performance, and energy■ Development of methods and instruments for:

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Food Chain Management Today

■ Waste of food

• About 50% of vegetables and fruits in

UK supermarkets have to be

disposed

• Just in UK: 17 million tons per year

• Disposal cost: about 20 billion Euro in

UK

<

Neither sustainable nor efficient nor effective

■ More traffic

• Higher delivery frequency

• Therefore more empty trucks

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Sustainable Food Chain Management

Rapid Testing Sensor Technology

Packing

AutoID

LogisticCustmoer ServiceWarehousing

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Santos

Buenos Aires

BremerhavenSantos

CKD-Anchieta

Bremerhaven

Pacheco

Buenos Aires

WedemarkSalzgitter

Carbon Footprint:Volkswagen Amarok Production

Hannover, Germany Pacheco, Argentina

SME

SupplierCross Dock

Harbour/Airport

Harbour/Airport Production

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Carbon Footprint:Volkswagen Amarok Production

■ Long and complex supply chain■ Parts variety: approx. 650 different parts■ Supplier variety: almost 400 European suppliers■ Different keeping quality: depends on the material, parts (e.g. tires)■ Obsolete materials: ramp-up and -down of parts■ Limited supplier capacity, high market demand: no flexibility for

significant deviation from forecast■ …

SME

SupplierCross Dock

Harbour/Airport

Harbour/Airport Production

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Global Supply Networks with many Locations cause Intransparency …

Inventories

ERP

PPS

BDE

Transport

Execution Systems

Goods Receipt

Goods Issue

Localization (GPS) Capacity Utilization Production Progress

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Real-Time Logistics: Fast Identification and Transparency

■ Challenges: ■ information must be available on time in full■ find standards for cross-company implementation of Real-Time

Auto-ID-Technologies (e.g. RFID)■ enable intelligent information sharing, execution and event handling

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A new Software Approach to Evaluate Global Ecological Sustainability

combining ECOnomic & ECOlogic objectivesin Logistic Assistance Systems

DemandCapacityPlanning

TransportPlanning

SupplyChain

Monitoring

SupplyChain

Simulation

DemandCapacityPlanning

TransportPlanning

SupplyChain

Monitoring

SupplyChain

Simulation

eLog@istics Award 2011

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ECO2LAS: Carbon Footprint for the Supply Chain

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Sustainable Resource Efficiency: BETA Project at FIAT Betim, Brazil

World Class

Logistics

Security

Lean Logistics

IT/WMS

Equip-ment

■ Initial Situation:■ FIASA (Fiat Automoveis SA): 3.150 cars/da

(14 models)■ FPT (Fiat Powertrain): 3.300 engines +

3.500 transmissions■ LSPs for all in-plant-logistics for over 15

years

■ BETA Project (started in 02/2012):■ Insourcing of all logistics activities in FIASA

and FPT■ Goals:

■ Better quality of logistics processes■ Improve security■ Reduce Logistics Costs

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■ Structuring and mapping of Logistics processes■ Transparency on current logistics

processes■ Identification of cirtical procedures■ International Bench Marking (Best

Practices)

■ Define short-, medium- and long-term improvements

■ Develoment and mapping of ToBe-Proecesses■ Document new standard processes ■ Roll out of best practices in all shops■ Keep knowledge of processes■ Facilitate continuous improvement

Receiving Storage Line Feeding

LoadCheck

Truck entry

Emptiesload

Truck exit

Goodsreceipt

Label print

Storage

Buffer

Line demand

Material Picking

Delivery

Sustainable Resource Efficiency: BETA Project at FIAT Betim, Brazil

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Sustainable Noise Emissions: Urbanization meets Factory

Current Plant and Supplier Concept■Minimize stock levels and coherent lot sizes through in time supply■Just-in-time supply of components with reduced delivery quantity and higher frequency

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Sustainable Noise Emissions: Evaluation of Future Scenarios

Direct nesxt to plant Distance Cluster 1 (DC 1) DC 2 DC 3

Ext. Warehouse and Cross DockOEM

Seats

Special Supply

Tires

Engines

Palets, Boxes (GLT)

Small Boxes (KLT)

Standard Supply

Vehicles

Fully Build Up Units (FBU)

■ Analyze of different distance clusters and supply concepts to find solutions which reduce noise and gas emissions and guarantee reliable cost efficient supply.

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OEM

Ext. Warehouses(e. g. Cross Docks,

Highway Border

Urb

aniz

ed A

rea

Supp

lier L

ocat

ions

Distribution Route

Distance Cluster 3

Distance Cluster 2

Distance Cluster 1

Sustainable Noise Emissions: a new Paradigm

■ Simulation based study of different future scenarios (demand, structure, processes).

■ Evaluation of transports, gas and noise emissions and identification of sustainable supply strategies.

■ Identification of a Road-Map for future supply chain management.

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Multishuttle Move – a new Material Flow Paradigm inside the Factory

Diese Entwicklung wurde gefördert durch:

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Diversity of Logistics – Sustainability is a mayor Issue!

© Fraunhofer IML

Dr.-Ing. Michael Toth

phone: +49 231 9743 169fax: +49 231 9743 234

email: [email protected] IML

Logistics: connecting ...... and communicating!

Muito obrigado pela atenção!