Ford lio-Ho Material Planning And Logistics 福特六和物料規劃與運籌MP&L ManagerA.L.Fan范阿浪協理Ford Production System and Vision,MP&L Mission, Role and Responsibility of MP&LModel Line-Up ComplexityProduction Schedule and ReleaseMP&L Exterior and Internal LogisticsCommon Material Management SystemIntroduction of FLH MP&L 介紹內容何謂福特生產系統(FPS)?福特生產系統(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。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(FPS Vision)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福特生產系統的執行福特產品開發系統FPDS售後服務.Sales & Services.Quality Care.Customer Satisfaction.GQRS從訂單到交車(Order to Delivery)福特生產系統FPS6Sigma /VCATS / TQE CMIDCDAPA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資訊流物料流運輸供應鍊圖供應商排程Cost structure 成本結構 Mission Of Material Planning and Logistic物料規劃與運籌之使命To optimize the global supply chain through:1.Synchronous flow of information.2.Synchronous flow of material.3.Coordination of the overall process of production .MP&L Role and Responsibility物料規劃與運籌之角色與責任Synchronous Material FlowSynchronous Information FlowOptimized Supply ChainRight MaterialStable and Accurate information flowMinimal InventoryRight QualityData formal enables transformation from data to knowledge to predictabilityMinimal ExpendingRight PackingMinimal Lead- timeRight LocationRight TimeOptimized LogisticRight TimeLowest Total CostMP&L Metrics 物料規劃與運籌之衡量指數Build toScheduleDock toDockOEENumber of Parts On Pull ReplenishmentInventory TurnBuild to orderIM Fill RateTotal CostConveyancesOn WindowPre-Production preparation Production Scheduling & ReleaseImport PartsSupply ChainManagementInventoryControlIn-Plant Material HandlingLocal PartsSupply ChainManagementMajor Function Of Material Planning and Logistics物料規劃之組織與功能Model line and Complexity生產車型及物料一覽表ItemModelCat CodeMSCSourcePackPack SizeImport Parts ItemLocal Parts ItemNo of Consignment PartsModelCommonSatellite1C206 Tierra18MazdaLotNBLI18080720101019LIII12080J396020HB60402C224MAVPremacy4MazdaLotFord C2246040702109061Mazda J54403CD 132 Mondeo16EuropePXPPXP From Europe. Engine from Chihuahua, T/M from Batavia863875564U204 Escape8US IEOPXP Direct Sourced from US 14 parts770595149MCLot60205EII 8MCLot40900818216Pronto10SuzukiLot4879784668Total6447525234374Other Major Complexity其他主要複雜度Different Part Numbering SystemParts count near 10,000 (9,986)Engineering Change Control SystemClaim and PSPO (MPPO) SystemsLess Parts Commonization休旅車休旅車 轎車轎車商用車商用車FLH MPL-Exterior Logistics (Import)進口零件運籌概況圖JapanSuzukiProntoFord Lo Ho PlantUS IEO U204/J1414 Direct ship parts3.0 Engine2.0/3.0 T/MRGLMexicoChihuahua Eng.2.0CoughlinJapanMazadaC206EIIU204Japan Jatco2.5 Auto T/MEurope IEOCD132HuppertzH BuildingCD132PXP Weekly ShipmentTransit Time 51 Days(Including 16 Days Float)iPXP Weekly ShipmentTransit Time 10 DaysPXPWeekly ShipmentTransit Time 46 DaysLot Weekly ShipmentTransit Time 10 DaysFLH Local Components Logistics台灣本地零件概況North: 62 suppliersDelivery Time: 1-1.5HMajor Components :Stamping Parts/Trim Parts/Seat/Tire/ Chassis Parts/Color PartsMiddle : 12 SuppliersDelivery Time: 34HSouth : 11 SuppliersDelivery Time: 5-6H Total Q1 Suppliers : 85Major Components:Hand-on Parts/Wiring/Lamp/Piston etc.Major Components:Door Trim/Parking Cable/Glass/Top ceiling piston pin etc.FLH BOM/ Material management System零件表之管理WERS/TESS Engineering ReleaseEngineering BOMManufacturing BOM Establishment & maintenanceEngineering Change control and management ECN Notice KDLocalCMMS3M|BOMTPCRDeviation Source change control. Spec. /usage clarification. BOM Maintenance. Obsolescence control. Product feature change Order to Delivery 從接訂單到交車生產計劃與訂料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1.零件情況零件情況2.工廠產能工廠產能3.車型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1.1. 4545天的天的計劃計劃2. 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CKDCKD1.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Material Requirement Releasing Process for Special Vehicle Orders from Dealers特別訂單車的物料作業程序 Illustration:1.Every SVO is built on a base model2.Added and deleted part list is derived from the base modelThe Numbers:Jan : 305Feb: 137Mar: 45Apr: 111May: 205Jun: 73Total: 876 unitsRelease of the Normal Production Parts of the Base ModelRelease of the Added Parts to the Base ModelRelease 交貨單的產生Ford Products CD132 ( Vehicle Line CNE )WERSCMMSWIPSSOLMISSupplierNON-Ford Products Mazda, Suzuki and Ford Mazda U204 Import Parts:Import Parts:KD Lot OrderBy MSC. LotKD SourceLocal PartsLocal Parts: :TESS(Manual)CMMSWIPSSOLMISSupplierFLH Vendor Release system物料交貨通知系統KD Lot Ordering & Supply Timing Frame (Japan) 批量訂購與供應時間AA+1A+2A+3A+4Firm Order For Month A+2 PackingFor Month A+3 ProductionPacking For The 1 St ShipmentParts On The SeaCustoms Clearance1St Shipment IN-Plant For Production123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051parts leave trading companycustom clearence & in-plant, 3 daysready for production16 days floatTransit time 35 daysRemarks:System set-upWe 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 days2. Trading Company to Port: 5 days3. Custom & Clearance : 3 days4. Safety Float Stocks : 16 daysRelease lead time prior to production1. 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 packing, part requirements for production in a specific week should be firmed 74 days in advance.Vessels leave RotterdamBut FLH parts not loadedVessels leave RotterdamVessels leave FelixstoweLeave AntwerpenVessel leave SouthamptonAPLK Line2nd Ocean Freight Route, K Line5 Days27 Days1st Ocean Freight Route, APLSystem Set Up for European Logistics單件訂購之時間設定(2)(6)(1)(3)(4)Total measure of area: 341,650 square meterFLH Vehicle Information System車輛資訊系統Vehicle InformationSystemSupplierBodyPaintFAP-1FAP-2WarehouseDealerShippingCAI FinalPBSOn TrimCAIAllocationPrimerFLH 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.In-plant & Out-plant Sequential Feeding (ILVS) 廠內廠外序列交貨方式Supplier AAA ABBMarket Area (574 parts)CCCCDDFFFECCCCDDAAA ABBFFFEPBS1.PBS pass the production sequence information to the Picking station 2.The operator picks the parts according to production sequence and put in the trolley in sequence 3.The operator deliver the parts with trolley to the fit of point(1)AAA ABB(2)(3)Benefits: To save line side space and reduce operator workload handling parts complexity (Out-plant: 324 parts)Color Parts Delivery Process 顏色零件之交貨程序BodyAllocationFord Lio HoSuppliersSend 1+6 BodyAllocation at 3:30 PME mailMulti frequency delivery base on on-to-primer informationILVS delivery for Bumper, side skirtSMART OfficeAAA ABBFFFECCCCDDFillActiveFillActiveFillActiveA-01A-03AAAAAAAAAAAABBCCBBBBBBBBDDDDDDCCCCCCPart CPart BPart APart DDDZone MailboxKan-Ban Part Process 看板供料程序Serial NumberLinesideMailboxLinesideMailboxOperator AOperator BWorkgroup LeaderMHBenefits: 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 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 sent back to Market Mailbox are the number of containers to be delivered to the line side Line Feeder BMarket Area (764 parts)Line Feeder AMarket Mailbox AMarket Mailbox A7:20 AM7:30 AM7:40 AMCall Parts Process 呼叫供料 Part Number SMART No Market Address Line Side AddressF7C6-5422401-AG 000122 DTL-A-02 E26-N-010F8C6-5426075-AA 005126 DTL-A-03 E27-S-020F7C6-5467934-AB 003412 DTL-A-01 E26-N-030Call light boardABCABCBCall button Market Area (269 parts)Benefits: To minimize stock levels at line side and spare out spaces for the new parts of new model.1.The operator pushes the call button to request the part he needs. 2.The light on the call light board for the part will be fleshing indicating the part has being requested3.The line feeder pushes the reset button on the Reset panel reset4.The linefeed come to market area to pick the part and deliver to the fit of point(1)(2)OnOffOnOffOnOffABC Reset panel(3)(4)Call buttonCall buttonTotal: 269 partsInventory Control Process庫存管理程序Pack SizeConfirmationFloat DayParameter Set-up in CMMSWeekly On-Site ReviewInventoryObjectiveSet-upInventoryPerformanceReviewContinuousImprovementForm-1121 Confirmation.By Each AnalystMonthly inventory Performance review by Each AnalystFollow up Action Plan Safety Stock/Adv.Job Shipping FrequencyOrg Review Team Material Control物料管理福特生產系統小組活動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倡導每一位員工對物料的新觀念以合乎同步物流的要求的要求防止刮傷人人有責防止刮傷人人有責紅桌物料檢討紅桌物料檢討物料改善會議物料改善會議庫存檢討改善會議庫存檢討改善會議門禁門禁Model B/out Management process車種結束物料管理程序DiscontinueParts ListFirst Cycle CountSecondCycle CountSpecialCycle CountAnalyst submit the listsSpecial count for Local- import parts 3 months before balance outAdjust BOH.Special Count one month before Balance outAdjust BOH.Special Count by MSCMS-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。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 Supplier Delivery Performance協力廠商交貨實績Criteria1.ASN Achievement:30%2.Timeliness:20%3.Shipping Discrepancy:20%4.Over shipment:5%5.Packaging: 15%6.Problem Report:10% 執行Six Sigma 的現況2000年開始推廣Six Sigma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/專案通用物流管理系統進口零件來源，訂購及包裝方式JapanSuzukiProntoUS IEO U204/J1414 Direct ship parts3.0 Engine2.0/3.0 T/MMexicoChihuahua Eng.2.0JapanMazadaC206EIIU204Japan Jatco2.5 Auto T/MEurope IEOCD132HuppertzH BuildingCD132RGLCoughlinPXP Weekly ShipmentTransit Time 51 Days(Including 16 Days Float)iPXP Weekly ShipmentTransit Time 46 DaysLot Weekly ShipmentTransit Time 10 DaysPXP Weekly ShipmentTransit Time 10 DaysFord Lo Ho PlantPart By Part Part By Part 訂購訂購 (M(Metrostar)etrostar)批量訂購批量訂購 ( (其他車種其他車種 Mazda, Suzuki and Ford U204) Mazda, Suzuki and Ford U204) 以車型車種別以批量訂購KD Lot Order By MSC. Lot國外供應商KD Source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Bridge Interface Between Corporate & Local SystemNew Module To Be DevelopedCorporate SystemExisting Local SystemCMMS3 - CD132Part Usage - VBOMWIPSATPSourcingSOLMISTradingCompanyUS SupplierMailbox FLH Local SupplierRelease (CIF830/862) ASN(CIF856)VISMailboxEuropean System-MSC EOCSFIEXCEL FileDaily/MonthlyVehicleSchedule CatCode to EOCForecast/Offline/Order Line-upAccountsPayableMailboxReceipt (1-32)Actual PriceApproved Tooling DataReceiptActual PriceApproved Tooling DataPANDAMailboxUnit CostFAPCCommitted Tooling DataICSImport partsprice mark-upPrice Look-upPrice Look-upMailboxMultiple BridgesImport PartsCMMS3ASN(web-based)Vehicle Cost AccountingMQ Series SourcingMSC to SFI ConversionMailboxMailboxMailboxEuropean SupplierTaiwan Forecast/Scheduling Feeds to CMMS3TAIWAN LOCAL SYSTEM (VIS)CatCode/EOC TableKD LotEmerging MktsForecastProcessEmerging MktsSchedulingProcess-GPAM SolveCumCountsCMMS3CatCode ToEOC FileCatCodeTo EOCCatCodeForecastBy PeriodSegmented/SequencedOrder Line-upEOCDay 0Prod (Offline)Body & Assyplus Captive Seq. OrderLine-upEOCSFI Counts TYD Prod Day-1(Bridge 3-43)SFIEOCDay 0 Offline & Captive SeqConfirmed Order Line-upGPAM TableOp Plan for TaiwanEvent Table for TaiwanMaterial Forecast SFI by dayEvent TableOp Plan(Bridge 3-43)(Bridge 3-42) (Bridge 3-44) EXCEL FILE =Daily & MonthlyVehicleSchedule批量(Lot Kit) 訂購與 Part By Part 訂購與包裝PartsUsage/ Pack12345A4B1C5D3E2PartsPack123456789101112A6B12C7D5E10最低包裝量最低包裝量最低訂購量最低訂購量 (Common Material Management System) 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)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福特六和公司七名優秀員工參與配合導入計劃通用物流管理系統導入時程表通用物流管理系統Feb.21 2000 完成 CMMS3 系統連接 FLH 內部網路Feb.28 2000 WERS 與 CMMS3 Plant Code FI1LF 連結 (BOM)May 29 2000 WIPS 連接 (Parts Sourcing) Jun.01 2000核準BOM (Bill Of Material)Jul.31 2000車輛需求及預測資料(Forecast & Order)的試送及確認Aug.14 2000完成零件交貨通知連接至供應商 (SOLMISFLH ASN)Dec.04 2000 CMMS3 Full Production 正式啟用及首次收料Jan.06 2001CD132 (Metrostar)開始試裝Jun.04 2001 CD132 Job#1Dec 31 2001 完成其他車種本地零件之應用PXP VS KD LOT 成本比較(At migration, normalized FLH costs)成本Per Unit(US$)CDW 162(KD)CD132(PXP)PXP(B/W) KD防鏽/包裝Oiling/boxing$729$246$483海運費/陸運費Sea freight /landing6290(29)空運費Airfreight12(1)進口稅Duty1385979報廢Obsolescence1266存貨Inventory Carrying Cost-44(44)人工Manpower Increase-67(67)設備折舊Facility Depreciation & Others-7(7)合計Total Cost Impact Per Unit$941$521$420競 爭 優 勢國際觀全球化之物流系統去執行全球採購與物料跟催，達到全球化專業分工與策略聯盟之目的。福特六和為全亞洲與北美第一個汽車裝配廠導入CMMS3 系統(通用物流管理系統)的工廠。CMMS3提供最及時之物料移動狀況及庫存狀況，結合福特生產系統同步化物流與JIT之物流管理之精神。成本效益存貨水準更容易控制與管理，達到物流成本極小化之目標。彈性化之生產以零件為訂貨單位，生產更具彈性化，使顧客滿意達到極大化。全球IT資源分享，減少系統發展之投資成本。拓展外銷商機C206 L3 Parts Export Operation Tierra 零件外銷東南亞FMI (Indonesia)IPM: Mar 2002Job1: Apr 2002Volume: 873 Units/YFM (Malaysia) IPM : Sep. 2000 Job1: Mar. 2001Volume: 1,080 Units/YFVL (Vietnam) IPM : Jan. 2002 Job1: Mar. 2002Volume: 1,860 Units/YFMCP (Philippines)IPM: Sep 2001Job1 Feb 2002Volume:3,698 Units/YFSST (Thailand)IPM: Feb 2002Job1: Mar 2002Volume: 2,400 Units/Y JapanJapanS. AfricaS. AfricaTaiwanTaiwanEuropeEuropePhilippinesPhilippinesMalaysiaMalaysiaVietnamVietnamPhilippinesPhilippinesTaiwanTaiwanKD Lot SupplierKD Lot SupplierSupply Chain Mapping 策略聯盟與專業分工Material SourcesMaterial Sources S. AfricaS. AfricaLot AssemblyLot AssemblyLot AssemblyLot AssemblyThailandThailandMalaysiaMalaysiaLocal SuppliersLocal SuppliersLocal SuppliersLocal SuppliersLocal SuppliersLocal SuppliersLocal SuppliersLocal SuppliersLocal SuppliersLocal SuppliersPxP PxP Assembly AssemblyKD Lots required for Malaysia and Vietnam due to low volume,KD Lots required for Malaysia and Vietnam due to low volume,Lack of local systems capability, and developing experience inLack of local systems capability, and developing experience inA PxP environmentA PxP environmentKoreaChina謝謝各位