WMS (Warehouse Management Systems · WMS -SILS Centers 17 Nov 2005 page 11 • EDS Internal SILS in Supply Chain SILS CenterSILS Center OEM TIER 1 DELFOR PUS Sequenced Product Sequencing

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


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


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


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


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.


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


• 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


…… 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


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


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


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


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


• 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


SILS SILS -- System OverviewSystem Overview

EDI

ORDERS

DELIVERY

PICKING

PACKING

BIN HANDLING

LOADING

RECEIVING

STORAGE &

RETRIEVAL

SHIPMENT

SEQUENCINGSEQUENCING


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


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


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


SILS SILS –– Delivery point Delivery point -- Concept OverviewConcept Overview

SILS Center

OEM Plant

Hand-over

point

TIER 1


• 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


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


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.


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


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


Case study

ILPA

SILS CentreSequencing Serviceof Production Parts


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


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 %


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


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


Block StorageBlock Storage

Service:

• block storage for stackable goods

• block storage for oversized packaging

• A-item with a high inventory range

(high replacement time)


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 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



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 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



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




100 m

Variante 1

10

116

14

Office

QS

Desp

atchA

rea

180 m

Variance 1Variance 1




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


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.


Door - Line Cockpit -Line

receiving

Line FeedingLine Feeding


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


EmergencyEmergency issuesissues

incoming goods inspection

FIFO - principle

packaging development support

inventory level control

permanent physical inventory

maintenance agreements (contracts)

✔

✔

✔

✔

✔

✔


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

EDSEDS

Avd Gomez Laguna 25Avd Gomez Laguna 25

ZaragozaZaragoza

+34 976767000+34 976767000

[email protected]@eds.com

Questions and Comments

Documents

WMS (Warehouse Management Systems · WMS -SILS Centers 17 Nov 2005 page 11 • EDS Internal SILS in Supply Chain SILS CenterSILS Center OEM TIER 1 DELFOR PUS Sequenced Product Sequencing