福特汽车---物料规划与运筹

1Fordlio-HoMaterialPlanningAndLogistics福特六和物料規劃與運籌MP&LManagerA.L.Fan范阿浪協理2FordProductionSystemandVision,MP&LMission,RoleandResponsibilityofMP&LModelLine-UpComplexityProductionScheduleandReleaseMP&LExteriorandInternalLogisticsCommonMaterialManagementSystemIntroductionofFLHMP&L介紹內容3何謂福特生產系統(FPS)?福特生產系統(FordProductionSystem)–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(FPSVision)5FPS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6福特生產系統的執行福特產品開發系統FPDS售後服務.Sales&Services.QualityCare.CustomerSatisfaction.GQRS從訂單到交車(OrdertoDelivery)福特生產系統FPS6Sigma/VCATS/TQECMIDCDAPA7執行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規劃資訊流物料流運輸供應鍊圖供應商排程8Coststructure成本結構MaterialVar.MarketingLaborO/HDutyFixMarketingToolingOthers9MissionOfMaterialPlanningandLogistic物料規劃與運籌之使命Tooptimizetheglobalsupplychainthrough:1.Synchronousflowofinformation.2.Synchronousflowofmaterial.3.Coordinationoftheoverallprocessofproduction.10MP&LRoleandResponsibility物料規劃與運籌之角色與責任SynchronousMaterialFlowSynchronousInformationFlowOptimizedSupplyChainRightMaterialStableandAccurateinformationflowMinimalInventoryRightQualityDataformalenablestransformationfromdatatoknowledgetopredictabilityMinimalExpendingRightPackingMinimalLead-timeRightLocationRightTimeOptimizedLogisticRightTimeLowestTotalCost11MP&LMetrics物料規劃與運籌之衡量指數BuildtoScheduleDocktoDockOEENumberofPartsOnPullReplenishmentInventoryTurnBuildtoorderIMFillRateTotalCostConveyancesOnWindow12Pre-ProductionpreparationProductionScheduling&ReleaseImportPartsSupplyChainManagementInventoryControlIn-PlantMaterialHandlingLocalPartsSupplyChainManagementMajorFunctionOfMaterialPlanningandLogistics物料規劃之組織與功能13ModellineandComplexity生產車型及物料一覽表ItemModelCatCodeMSCSourcePackPackSizeImportPartsItemLocalPartsItemNoofConsignmentPartsModelCommonSatellite1C206Tierra18MazdaLotNBLI18080720101019LIII12080J396020HB60402C224MAVPremacy4MazdaLotFordC2246040702109061MazdaJ54403CD132Mondeo16EuropePXPPXPFromEurope.EnginefromChihuahua,T/MfromBatavia863875564U204Escape8USIEOPXPDirectSourcedfromUS14parts770595149MCLot60205EII8MCLot40900818216Pronto10SuzukiLot4879784668Total644752523437414OtherMajorComplexity其他主要複雜度DifferentPartNumberingSystemPartscountnear10,000(9,986)EngineeringChangeControlSystemClaimandPSPO(MPPO)SystemsLessPartsCommonization休旅車轎車商用車15FLHMPL-ExteriorLogistics(Import)進口零件運籌概況圖JapanSuzukiProntoFordLoHoPlantUSIEOU204/J1414Directshipparts3.0Engine2.0/3.0T/MRGLMexicoChihuahuaEng.2.0CoughlinJapanMazadaC206EIIU204JapanJatco2.5AutoT/MEuropeIEOCD132HuppertzHBuildingCD132PXPWeeklyShipmentTransitTime51Days(Including16DaysFloat)iPXPWeeklyShipmentTransitTime10DaysPXPWeeklyShipmentTransitTime46DaysLotWeeklyShipmentTransitTime10Days16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義台南高雄台東花蓮FLHLocalComponentsLogistics台灣本地零件概況North:62suppliersDeliveryTime:1-1.5HMajorComponents:StampingParts/TrimParts/Seat/Tire/ChassisParts/ColorPartsMiddle:12SuppliersDeliveryTime:3~4HSouth:11SuppliersDeliveryTime:5-6HTotalQ1Suppliers:85MajorComponents:Hand-onParts/Wiring/Lamp/Pistonetc.MajorComponents:DoorTrim/ParkingCable/Glass/Topceilingpistonpinetc.17FLHBOM/MaterialmanagementSystem零件表之管理WERS/TESSEngineeringReleaseEngineeringBOMManufacturingBOMEstablishment&maintenanceEngineeringChangecontrolandmanagementECNNoticeKDLocalCMMS3M|BOMTPCRDeviation•Sourcechangecontrol.•Spec./usageclarification.•BOMMaintenance.•Obsolescencecontrol.•Productfeaturechange18OrdertoDelivery從接訂單到交車19生產計劃與訂料A月的20日在生產計劃會議上決定A+1月的需求生產計劃的考量因素1.零件情況2.工廠產能3.車型車種之平均與平準以CMMS3發出交貨通知單1.45天的計劃2.12個月的預估量每日生產報告為CD132發出單一零件A+4月的交貨通知單批購CKD1.A+3月2.A+4月15%及A+5月20%的變動量進口零件到廠監控A+3月的船期監控進口零件的庫存量及倉儲遲滯費用的發生與各工廠主任討論生產計劃生產計劃與本地零件的訂購進口零件的訂購`20MaterialRequirementReleasingProcessforSpecialVehicleOrdersfromDealers特別訂單車的物料作業程序Illustration:1.EverySVOisbuiltonabasemodel2.AddedanddeletedpartlistisderivedfromthebasemodelTheNumbers:Jan:305Feb:137Mar:45Apr:111May:205Jun:73Total:876unitsReleaseoftheNormalProductionPartsoftheBaseModelReleaseoftheAddedPartstotheBaseModel21Release交貨單的產生FordProductsCD132(VehicleLineCNE)WERSCMMSWIPSSOLMISSupplierNON-FordProductsMazda,SuzukiandFordMazdaU204ImportParts:KDLotOrderByMSC.LotKDSourceLocalParts:TESS(Manual)CMMSWIPSSOLMISSupplier22FLHVendorReleasesystem物料交貨通知系統Forecast•45DaysDailyRequirement•12MonthsForecastrequirement•OrderLineUp•DealerOrder(FromSIDOBank)tobeMaintained14DaysVISEmergingMktsSch.Process•GPAMSolve,NiehlCologne,GermanyCMMS3•Float•Transittime•%ofBusiness•OthersVenderRelease•Daily(862)Local•Weekly(830)Local&Import•3MonthsWeekly•3MonthsMonthly23KDLotOrdering&SupplyTimingFrame(Japan)批量訂購與供應時間AA+1A+2A+3A+4FirmOrderForMonthA+2PackingForMonthA+3ProductionPackingForThe1StShipmentPartsOnTheSeaCustomsClearance1StShipmentIN-Pl