福特汽车－物料规划与运筹

1、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1Ford Production S 拥有庞大的管理资料库stem and Vision,MP&L Mission, Role and R 拥有庞大的管理资料库 of MP&LModel Line-Up C 拥有庞大的管理资料库Production Schedule and ReleaseMP&L Exterior and Internal LogisticsCommon Material Management S 拥有庞大的管理资料库s

2、temIntroduction of FLH MP&L 介紹內容2何謂福特生產系統(FPS)?福特生產系統(Ford Production S 拥有庞大的管理资料库stem) 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。3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)4FPS精實(Lean)生產的5個階段性步驟 1穩定性

3、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5福特生產系統的執行福特產品開發系統FPDS售後服務.Sales & Services.Q 拥有庞大的管理资料库 Care.Customer Satisfaction.GQRS從訂單到交車(Order to D 拥有庞大的管理资料库)福特

4、生產系統FPS6Sigma /VCATS / TQE CMIDCDAPA6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7Cost structure 成本結構8 Mission Of Material Planning and Logistic物料規劃與運籌之使命To optimize the global 拥有庞大的管理资料库 chain through:S 拥有庞大的管理资料库nchronou

5、s flow of information.S 拥有庞大的管理资料库nchronous flow of material.Coordination of the overall process of production .9MP&L Role and R 拥有庞大的管理资料库物料規劃與運籌之角色與責任S 拥有庞大的管理资料库nchronous Material FlowS 拥有庞大的管理资料库nchronous Information FlowOptimized S 拥有庞大的管理资料库 ChainRight MaterialStable and Accurate information f

6、lowMinimal I 拥有庞大的管理资料库Right Q 拥有庞大的管理资料库Data formal enables transformation from data to knowledge to 拥有庞大的管理资料库Minimal ExpendingRight PackingMinimal Lead- timeRight LocationRight TimeOptimized LogisticRight TimeLowest Total Cost10MP&L Metrics 物料規劃與運籌之衡量指數Build toScheduleDock toDockOEENumber of Part

7、s On Pull ReplenishmentI 拥有庞大的管理资料库 TurnBuild to orderIM Fill RateTotal CostC 拥有庞大的管理资料库ancesOn Window11Pre-Production preparation Production Scheduling & ReleaseImport PartsS 拥有庞大的管理资料库 ChainManagementI 拥有庞大的管理资料库ControlIn-Plant Material HandlingLocal PartsS 拥有庞大的管理资料库 ChainManagementMajor Function

8、 Of Material Planning and Logistics物料規劃之組織與功能12Model line and C 拥有庞大的管理资料库生產車型及物料一覽表ItemModelCat CodeMSCSourcePackPack SizeImport Parts ItemLocal Parts ItemNo of Consignment PartsModelCommonSatellite1C206 Tierra18MazdaLotNBLI18080720101019LIII12080J396020HB60402C224MAVP 拥有庞大的管理资料库4MazdaLotFord C2246

9、040702109061Mazda J54403CD 132 Mondeo16EuropePXPPXP From Europe. Engine from Chihuahua, T/M from Batavia863875564U204 Escape8US IEOPXP Direct Sourced from US 14 parts770595149MCLot60205EII 8MCLot40900818216Pronto10SuzukiLot4879784668Total644752523437413Other Major C 拥有庞大的管理资料库其他主要複雜度Different Part N

10、umbering S 拥有庞大的管理资料库stemParts count near 10,000 (9,986)Engineering Change Control S 拥有庞大的管理资料库stemClaim and PSPO (MPPO) S 拥有庞大的管理资料库stemsLess Parts Commonization休旅車 轎車商用車14FLH 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

11、.0 T/MRGLMexicoChihuahua Eng.2.0CoughlinJapanMazadaC206EIIU204Japan Jatco2.5 Auto T/MEurope IEOCD132HuppertzH BuildingCD132PXP W 拥有庞大的管理资料库 ShipmentTransit Time 51 D 拥有庞大的管理资料库s(Including 16 D 拥有庞大的管理资料库s Float)iPXP W 拥有庞大的管理资料库 ShipmentTransit Time 10 D 拥有庞大的管理资料库sPXPW 拥有庞大的管理资料库 ShipmentTransit Ti

12、me 46 D 拥有庞大的管理资料库sLot W 拥有庞大的管理资料库 ShipmentTransit Time 10 D 拥有庞大的管理资料库s15FLH Local Components Logistics台灣本地零件概況North: 62 suppliersD 拥有庞大的管理资料库 Time: 1-1.5HMajor Components :Stamping Parts/Trim Parts/Seat/Tire/ Chassis Parts/Color PartsMiddle : 12 SuppliersD 拥有庞大的管理资料库 Time: 34HSouth : 11 Suppliers

13、D 拥有庞大的管理资料库 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.16FLH BOM/ Material management S 拥有庞大的管理资料库stem零件表之管理WERS/TESS Engineering ReleaseEngineering BOMManufacturing BOM Establishm

14、ent & maintenanceEngineering Change control and management ECN Notice KDLocalCMMS3M|BOMTPCRDeviation Source change control. Spec. /usage clarification. BOM Maintenance. Obsolescence control. Product feature change 17Order to D 拥有庞大的管理资料库 從接訂單到交車18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零件情況工廠產能車型車種

15、之平均與平準以CMMS3 發出交貨通知單 45天的計劃 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19Material Requirement Releasing Process for Special Vehicle Orders from Dealers特別訂單車的物料作業程序 Illustration:E 拥有庞大的管理资料库 SVO is built on a

16、base modelAdded and deleted part list is derived from the base modelThe Numbers:Jan : 305Feb: 137Mar: 45Apr: 111M 拥有庞大的管理资料库: 205Jun: 73Total: 876 unitsRelease of the Normal Production Parts of the Base ModelRelease of the Added Parts to the Base Model20Release 交貨單的產生Ford Products CD132 ( Vehicle Li

17、ne CNE )WERSCMMSWIPSSOLMISSupplierNON-Ford Products Mazda, Suzuki and Ford Mazda U204 Import Parts:KD Lot OrderB 拥有庞大的管理资料库 MSC. LotKD SourceLocal Parts:TESS(Manual)CMMSWIPSSOLMISSupplier21FLH Vendor Release 拥有庞大的管理资料库stem物料交貨通知系統Forecast45 D 拥有庞大的管理资料库s D 拥有庞大的管理资料库 Requirement12 Months Forecast re

18、quirementOrder Line UpDealer Order (From SIDO Bank) to be Maintained 14 D 拥有庞大的管理资料库sVISEmerging Mkts Sch.Process GPAM Solve,Niehl Cologne, G 拥有庞大的管理资料库CMMS3FloatTransit time% of BusinessOthers Vender Release D 拥有庞大的管理资料库 (862) Local W 拥有庞大的管理资料库 (830) Local & Import 3 Months W 拥有庞大的管理资料库 3 Months M

19、 拥有庞大的管理资料库22KD Lot Ordering & S 拥有庞大的管理资料库 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 Production23123456789101112131415161718192021222324252627282930313233

20、343536373839404142434445464748495051parts leave trading 拥有庞大的管理资料库custom clearence & in-plant, 3 拥有庞大的管理资料库s 拥有庞大的管理资料库 for production16 拥有庞大的管理资料库s floatTransit time 35 拥有庞大的管理资料库sRemarks:S 拥有庞大的管理资料库stem set-upWe set up total 51 拥有庞大的管理资料库s as the parameter of in-transit time for supplier release

21、calculation in CMMS3.The 51 拥有庞大的管理资料库s in-transit time includes:1. Vessel shipping on water: 27 拥有庞大的管理资料库s2. Trading C 拥有庞大的管理资料库 to Port: 5 拥有庞大的管理资料库s3. Custom & Clearance : 3 拥有庞大的管理资料库s4. S 拥有庞大的管理资料库 Float Stocks : 16 拥有庞大的管理资料库sRelease lead time prior to production1. In compliance with rules

22、 indicated in IEO 拥有庞大的管理资料库 manual, a 3-week lead time is required for fabrication at suppliers. Furthermore, another week of part 拥有庞大的管理资料库 and packing is needed.2. Combining all the lead time, including transit time, part fabricartion, 拥有庞大的管理资料库, and packing, part requirements for production in

23、 a specific week should be firmed 74 拥有庞大的管理资料库s in advance.Vessels leave RotterdamBut FLH parts not loadedVessels leave RotterdamVessels leave FelixstoweLeave AntwerpenVessel leave SouthamptonAPLK Line2nd Ocean Freight Route, K Line5 D 拥有庞大的管理资料库s27 D 拥有庞大的管理资料库s1st Ocean Freight Route, APLS 拥有庞大的管

24、理资料库stem Set Up for European Logistics單件訂購之時間設定24(2)(6)(1)(3)(4)Total measure of area: 341,650 square meter25FLH Vehicle Information S 拥有庞大的管理资料库stem車輛資訊系統Vehicle InformationS 拥有庞大的管理资料库stemSupplierB 拥有庞大的管理资料库PaintFAP-1FAP-2WarehouseDealerShippingCAI FinalPBSOn TrimCAIAllocationPrimer26FLH Vendor D

25、 拥有庞大的管理资料库 Pattern台灣本地零件交貨方式 1. ILVS D 拥有庞大的管理资料库: Seat, Tire, Side Skirt, Bumper, Door Trim Panel.(S 拥有庞大的管理资料库nchronized 拥有庞大的管理资料库 based on On-Line Information Broadcast S 拥有庞大的管理资料库stem 拥有庞大的管理资料库 PBS). 2. Kan Ban D 拥有庞大的管理资料库: B 拥有庞大的管理资料库 Parts, Large Scale Parts. 3. General MRP D 拥有庞大的管理资料库.

26、27In-plant & Out-plant Sequential Feeding (ILVS) 廠內廠外序列交貨方式Supplier AAAABBMarket Area (574 parts)CCCCDDFFFECCCCDDAAAABBFFFEPBSPBS pass the production sequence information to the Picking station The operator picks the parts according to production sequence and put in the 拥有庞大的管理资料库 in sequence The op

27、erator deliver the parts with 拥有庞大的管理资料库 to the fit of point(1)AAAABB(2)(3)Benefits: To save line side space and reduce operator workload handling parts 拥有庞大的管理资料库 (Out-plant: 324 parts)28Color Parts D 拥有庞大的管理资料库 Process 顏色零件之交貨程序B 拥有庞大的管理资料库AllocationFord Lio HoSuppliersSend 1+6 B 拥有庞大的管理资料库Allocat

28、ion at 3:30 PME mailMulti 拥有庞大的管理资料库 拥有庞大的管理资料库 base on on-to-primer informationILVS 拥有庞大的管理资料库 for Bumper, side skirt29SMART OfficeAAAABBFFFECCCCDDFillActiveFillActiveFillActiveA-01A-03AAAAAAAAAAAABBCCBBBBBBBBDDDDDDCCCCCCPart CPart BPart APart DDDZone MailboxKan-Ban Part Process 看板供料程序Serial Number

29、LinesideMailboxLinesideMailboxOperator AOperator BWorkgroup LeaderMHBenefits: To keep line side 拥有庞大的管理资料库 at a minimum level, improve 5S and reduce 拥有庞大的管理资料库 拥有庞大的管理资料库 1. The operator picks the kan-ban attached in the container when he uses the first piece of the part. 2. The workgroup leader col

30、lects the kan-ban in Line side Mailboxes and sends them to Zone Mailbox 拥有庞大的管理资料库 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

31、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 AM30Call 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

32、 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.The operator pushes the call button to request the part he needs. The light on the call lig

33、ht board for the part will be fleshing indicating the part has being requestedThe line feeder pushes the reset button on the Reset panel resetThe 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 pa

34、rts31I 拥有庞大的管理资料库 Control Process庫存管理程序Pack SizeConfirmationFloat D 拥有庞大的管理资料库Parameter Set-up in CMMSW 拥有庞大的管理资料库 On-Site ReviewI 拥有庞大的管理资料库ObjectiveSet-upI 拥有庞大的管理资料库PerformanceReviewContinuousImprovementForm-1121 Confirmation.B 拥有庞大的管理资料库 Each A 拥有庞大的管理资料库stM 拥有庞大的管理资料库 拥有庞大的管理资料库 Performance rev

35、iew 拥有庞大的管理资料库 Each A 拥有庞大的管理资料库stFollow up Action Plan S 拥有庞大的管理资料库 Stock/Adv.Job Shipping F 拥有庞大的管理资料库Org Review Team 32Material Control物料管理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的要求防止刮傷人人有責紅桌物料檢討物料改善會議庫存檢討改善會議門禁33Model B/out Management process車種結束物料管理程序DiscontinueParts ListFirst C 拥有庞大的管理资料库cle CountSeco

36、ndC 拥有庞大的管理资料库cle CountSpecialC 拥有庞大的管理资料库cle CountA 拥有庞大的管理资料库st submit the listsSpecial count for Local- import parts 3 months before balance outAdjust BOH.Special Count one month before Balance outAdjust BOH.Special Count 拥有庞大的管理资料库 MSC34MS-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

37、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。35MS-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

38、 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36 Supplier D 拥有庞大的管理资料库 Performance協力廠商交貨實績CriteriaASN Achievement:30%Timeliness:20%Shipping D 拥有庞大的管理资料库:20%Over shipment:5%Packaging: 15%Problem Report:10%37 執行Six Sigma 的現況

39、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38通用物流管理系統39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 BuildingCD132RGLCou

40、ghlinPXP W 拥有庞大的管理资料库 ShipmentTransit Time 51 D 拥有庞大的管理资料库s(Including 16 D 拥有庞大的管理资料库s Float)iPXP W 拥有庞大的管理资料库 ShipmentTransit Time 46 D 拥有庞大的管理资料库sLot W 拥有庞大的管理资料库 ShipmentTransit Time 10 D 拥有庞大的管理资料库sPXP W 拥有庞大的管理资料库 ShipmentTransit Time 10 D 拥有庞大的管理资料库sFord Lo Ho Plant40Part B 拥有庞大的管理资料库 Part 訂購

41、(Metrostar)批量訂購 (其他車種 Mazda, Suzuki and Ford U204) 以車型車種別以批量訂購KD Lot Order B 拥有庞大的管理资料库 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41Bridge Interface Between Corporate & Local S 拥有庞大的管理资料库stemNew Module To Be DevelopedCorporate S 拥有庞大的管理资料库stemExisting Local S 拥有庞大的管理资料库ste

42、mCMMS3 - CD132Part Usage - VBOMWIPSATPSourcingSOLMISTradingC 拥有庞大的管理资料库US SupplierMailbox FLH Local SupplierRelease (CIF830/862) ASN(CIF856)VISMailboxEuropean S 拥有庞大的管理资料库stem-MSC EOCSFIEXCEL FileD 拥有庞大的管理资料库/M 拥有庞大的管理资料库VehicleSchedule CatCode to EOCForecast/Offline/Order Line-upAccountsP 拥有庞大的管理资料

43、库ableMailboxReceipt (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 t

44、o SFI ConversionMailboxMailboxMailboxEuropean Supplier42Taiwan Forecast/Scheduling Feeds to CMMS3TAIWAN LOCAL S 拥有庞大的管理资料库STEM (VIS)CatCode/EOC TableKD LotEmerging MktsForecastProcessEmerging MktsSchedulingProcess-GPAM SolveCumCountsCMMS3CatCode ToEOC FileCatCodeTo EOCCatCodeForecastB 拥有庞大的管理资料库 Per

45、iodSegmented/SequencedOrder Line-upEOCD 拥有庞大的管理资料库 0Prod (Offline)B 拥有庞大的管理资料库 & A 拥有庞大的管理资料库plus Captive Seq. OrderLine-upEOCSFI Counts T 拥有庞大的管理资料库D Prod D 拥有庞大的管理资料库-1(Bridge 3-43)SFIEOCD 拥有庞大的管理资料库 0 Offline & Captive SeqConfirmed Order Line-upGPAM TableOp Plan for TaiwanEvent Table for TaiwanMa

46、terial Forecast SFI 拥有庞大的管理资料库 拥有庞大的管理资料库Event TableOp Plan(Bridge 3-43)(Bridge 3-42) (Bridge 3-44) EXCEL FILE =D 拥有庞大的管理资料库 & M 拥有庞大的管理资料库VehicleSchedule43批量(Lot Kit) 訂購與 Part B 拥有庞大的管理资料库 Part 訂購與包裝PartsUsage/ Pack12345A4B1C5D3E2PartsPack123456789101112A6B12C7D5E10最低包裝量最低訂購量44 (Common Material Man

47、agement S 拥有庞大的管理资料库stem) 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)45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46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 2000WERS 與 CMMS3 Plant Code FI1LF 連結 (BOM)M 拥有庞大的管理资料库 29 2000WIPS 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 2000CMMS3 Full Production