某汽车六和物料规划与运筹报告

Fordlio-HoMaterialPlanningAndLogistics

福特六和物料規劃與運籌MP&LManagerA.L.Fan范阿浪協理1FordProductionSystemandVision,MP&LMission,RoleandResponsibilityofMP&LModelLine-UpComplexityProductionScheduleandReleaseMP&LExteriorandInternalLogisticsCommonMaterialManagementSystemIntroductionofFLHMP&L介紹內容2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。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(FPSVision)4FPS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.QualityCare.CustomerSatisfaction.GQRS從訂單到交車(OrdertoDelivery)福特生產系統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7Coststructure成本結構8

MissionOfMaterialPlanningandLogistic物料規劃與運籌之使命Tooptimizetheglobalsupplychainthrough:Synchronousflowofinformation.Synchronousflowofmaterial.Coordinationoftheoverallprocessofproduction.9MP&LRoleandResponsibility物料規劃與運運籌之角色與與責任SynchronousMaterialFlowSynchronousInformationFlowOptimizedSupplyChainRightMaterialStableandAccurateinformationflowMinimalInventoryRightQualityDataformalenablestransformationfromdatatoknowledgetopredictabilityMinimalExpendingRightPackingMinimalLead-timeRightLocationRightTimeOptimizedLogisticRightTimeLowestTotalCost10MP&LMetrics物料規劃與運運籌之衡量指指數BuildtoScheduleDocktoDockOEENumberofPartsOnPullReplenishmentInventoryTurnBuildtoorderIMFillRateTotalCostConveyancesOnWindow11Pre-ProductionpreparationProductionScheduling&ReleaseImportPartsSupplyChainManagementInventoryControlIn-PlantMaterialHandlingLocalPartsSupplyChainManagementMajorFunctionOfMaterialPlanningandLogistics物料規劃之組組織與功能12ModellineandComplexity生產車型及物物料一覽表ItemModelCatCodeMSCSourcePackPackSizeImportPartsItemLocalPartsItemNoofConsignmentPartsModelCommonSatellite1C206Tierra18MazdaLotNBLI18080720101019LIII12080J396020HB60402C224MAVPremacy4MazdaLotFordC2246040702109061MazdaJ54403CD132Mondeo16EuropePXPPXPFromEurope.EnginefromChihuahua,T/MfromBatavia863875564U204Escape8USIEOPXPDirectSourcedfromUS14parts770595149MCLot60205EII8MCLot40900818216Pronto10SuzukiLot4879784668Total644752523437413OtherMajorComplexity其他主要複雜雜度DifferentPartNumberingSystemPartscountnear10,000(9,986)EngineeringChangeControlSystemClaimandPSPO(MPPO)SystemsLessPartsCommonization休旅車轎車商用車14FLHMPL-ExteriorLogistics(Import)進口零件運運籌概況圖圖JapanSuzukiProntoFordLoHoPlantUSIEOU204/J1414Directshipparts3.0Engine2.0/3.0T/MRGLMexicoChihuahuaEng.2.0CoughlinJapanMazadaC206EIIU204JapanJatco2.5AutoT/MEuropeIEOCD132HuppertzHBuildingCD132PXPWeeklyShipmentTransitTime51Days(Including16DaysFloat)iPXPWeeklyShipmentTransitTime10DaysPXPWeeklyShipmentTransitTime46DaysLotWeeklyShipmentTransitTime10Days15FLHLocalComponentsLogistics台灣本地零零件概況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.16FLHBOM/MaterialmanagementSystem零件表之管管理WERS/TESSEngineeringReleaseEngineeringBOMManufacturingBOMEstablishment&maintenanceEngineeringChangecontrolandmanagement

ECNNotice

KDLocalCMMS3M|BOMTPCRDeviation

Sourcechangecontrol.Spec./usageclarification.BOMMaintenance.Obsolescencecontrol.Productfeaturechange17OrdertoDelivery從接訂單到到交車18生產計劃與與訂料A月的20日在生產計劃會會議上決定A+1月月的需求生產計劃的的考量因素素零件情況工廠產能車型車種之之平均與平平準以CMMS3發出出交貨通知45天的計劃12個月的預估量每日生產報報告為CD132發出單一零件A+4月的交貨通知單單批購CKD1.A+3月2.A+4月15%及A+5月20%的變變動量進口零件到到廠監控A+3月的船期監控進口零零件的庫存量及倉倉儲遲滯費用的發生與各工廠主主任討論生產計計劃生產計劃與與本地零件的訂訂購進口零件的訂購`19MaterialRequirementReleasingProcessforSpecialVehicleOrdersfromDealers特別訂單車車的物料作作業程序Illustration:EverySVOisbuiltonabasemodelAddedanddeletedpartlistisderivedfromthebasemodelTheNumbers:Jan:305Feb:137Mar:45Apr:111May:205Jun:73Total:876unitsReleaseoftheNormalProductionPartsoftheBaseModelReleaseoftheAddedPartstotheBaseModel20Release交貨單的產產生FordProductsCD132(VehicleLineCNE)WERSCMMSWIPSSOLMISSupplierNON-FordProductsMazda,SuzukiandFordMazdaU204ImportParts:KDLotOrderByMSC.LotKDSourceLocalParts:TESS(Manual)CMMSWIPSSOLMISSupplier21FLHVendorReleasesystem物料交貨通通知系統Forecast45DaysDailyRequirement12MonthsForecastrequirementOrderLineUpDealerOrder(FromSIDOBank)tobeMaintained14DaysVISEmergingMktsSch.ProcessGPAMSolve,NiehlColCMMS3FloatTransittime%ofBusinessOthersVenderReleaseDaily(862)LocalWeekly(830)Local&Import3MonthsWeekly3MonthsMonthly22KDLotOrdering&SupplyTimingFrame(Japan)批量訂購購與供應應時間AA+1A+2A+3A+4FirmOrderForMonthA+2PackingForMonthA+3ProductionPackingForThe1StShipmentPartsOnTheSeaCustomsClearance1StShipmentIN-PlantForProduction23123456789101112131415161718192021222324252627282930313233343536373839404142434445464748495051partsleavetradingcompanycustomclearence&in-plant,3daysreadyforproduction16days'floatTransittime35daysRemarks:Systemset-upWesetuptotal51daysastheparameterofin-transittimeforsupplierreleasecalculationinCMMS3.The51daysin-transittimeincludes:1.Vesselshippingonwater:27days2.TradingCompanytoPort:5days3.Custom&Clearance:3days4.SafetyFloatStocks:16daysReleaseleadtimepriortoproduction1.IncompliancewithrulesindicatedinIEOsupplymanual,a3-weekleadtimeisrequiredforfabricationatsuppliers.Furthermore,anotherweekofpartdeliveryandpackingisneeded.2.Combiningalltheleadtime,includingtransittime,partfabricartion,delivery,andpacking,partrequirementsforproductioninaspecificweekshouldbefirmed74daysinadvance.VesselsleaveRotterdamButFLHpartsnotloadedVesselsleaveRotterdamVesselsleaveFelixstoweLeaveAntwerpenVesselleaveSouthamptonAPLKLine2ndOceanFreightRoute,KLine5Days27Days1stOceanFreightRoute,APLSystemSetUpforEuropeanLogistics單件訂購購之時間間設定24(2)(6)(1)(3)(4)Totalmeasureofarea:341,650squaremeter25FLHVehicleInformationSystem車輛資訊訊系統VehicleInformationSystemSupplierBodyPaintFAP-1FAP-2WarehouseDealerShippingCAIFinalPBSOnTrimCAIAllocationPrimer26FLHVendorDeliveryPattern台灣本地地零件交交貨方式式1.ILVSDelivery:•Seat,Tire,SideSkirt,Bumper,DoorTrimPanel.(SynchronizeddeliverybasedonOn-LineInformationBroadcastSystembyPBS).2.KanBanDelivery:•BodyParts,LargeScaleParts.3.GeneralMRPDelivery.27In-plant&Out-plantSequentialFeeding(ILVS)廠內廠外外序列交交貨方式式SupplierAAAABBMarketArea(574parts)CCCCDDFFFECCCCDDAAAABBFFFEPBSPBSpasstheproductionsequenceinformationtothePickingstationTheoperatorpicksthepartsaccordingtoproductionsequenceandputinthetrolleyinsequenceTheoperatordeliverthepartswithtrolleytothefitofpoint(1)AAAABB(2)(3)Benefits:Tosavelinesidespaceandreduceoperatorworkloadhandlingpart’scomplexity(Out-plant:324parts)28ColorPartsDeliveryProcess顏色零件件之交貨貨程序BodyAllocationFordLioHoSuppliersSend1+6BodyAllocationat3:30PMEmailMultifrequencydeliverybaseonon-to-primerinformationILVSdeliveryforBumper,sideskirt29SMARTOfficeAAAABBFFFECCCCDDFillActiveFillActiveFillActiveA-01A-03AAAAAAAAAAAA{{BBCCBBBBBBBBDDDDDDCCCCCCPartCPartBPartAPartDDDZoneMailboxKan-BanPartProcess看板供料程序序SerialNumberLinesideMailboxLinesideMailboxOperatorAOperatorBWorkgroupLeaderMHBenefits:Tokeeplinesideinventoryataminimumlevel,improve5Sandreduceemergencydelivery1.Theoperatorpicksthekan-banattachedinthecontainerwhenheusesthefirstpieceofthepart.2.Theworkgroupleadercollectsthekan-baninLinesideMailboxesandsendsthemtoZoneMailboxeverythreehours.3.MHcollectsthekan-baninZoneMailboxesandsendsthemtoSMARTOfficeforsortingandputtingthemindifferentMarketMailbox.4.Thenumberofthekan-bansentbacktoMarketMailboxarethenumberofcontainerstobedeliveredtothelinesideLineFeederBMarketArea(764parts)LineFeederAMarketMailboxAMarketMailboxA7:20AM7:30AM7:40AM30CallPartsProcess呼呼叫供料PartNumberSMARTNoMarketAddressLineSideAddressF7C6-5422401-AG000122DTL-A-02E26-N-010F8C6-5426075-AA005126DTL-A-03E27-S-020F7C6-5467934-AB003412DTL-A-01E26-N-030CalllightboardABCABCBCallbuttonMarketArea(269parts)Benefits:Tominimizestocklevelsatlinesideandspareoutspacesforthenewpartsofnewmodel.Theoperatorpushesthecallbuttontorequestthepartheneeds.ThelightonthecalllightboardforthepartwillbefleshingindicatingtheparthasbeingrequestedThelinefeederpushestheresetbuttonontheResetpanelresetThelinefeedcometomarketareatopickthepartanddelivertothefitofpoint(1)(2)OnOffOnOffOnOffABCResetpanel(3)(4)CallbuttonCallbuttonTotal:269parts31InventoryControlProcess庫存管理程序序PackSizeConfirmationFloatDayParameterSet-upinCMMSWeeklyOn-SiteReviewInventoryObjectiveSet-upInventoryPerformanceReviewContinuousImprovementForm-1121Confirmation.ByEachAnalystMonthlyinventoryPerformancereviewbyEachAnalystFollowupActionPlanSafetyStock/Adv.JobShippingFrequencyOrgReviewTeam32MaterialControl物料管理福特生產系統統小組活動倡導每一位員員工對物料的的新觀念以合合乎同步物流流的要求防止刮傷人人人有責紅桌物料檢討討物料改善會議議庫存檢討改善善會議門禁33ModelB/outManagementprocess車種結束物料料管理程序DiscontinuePartsListFirstCycleCountSecondCycleCountSpecialCycleCountAnalystsubmitthelistsSpecialcountforLocal-importparts3monthsbeforebalanceoutAdjustBOH.SpecialCountonemonthbeforeBalanceoutAdjustBOH.SpecialCountbyMSC34MS-9000物料管理系統統簡介MS-9000物料管管理系統為福福特汽車事業業總部根據ISO-9000及QS-9000之精神所發發展出來的物物料管理系統統及評估標準準，為最高的的物料規劃標標準。評分方法：評分依20要要項，每一要要項再依O、M、C及及CI（4））個層級問題題來評定，分分別給予每一一要項0~3分再以要項項的平均分數數乘以50來來計算，總分分範圍為0~150分。。基本要要求條條件：最低必必要條條件－－新廠廠商80分分以上上，且且各項項問題題評分分不得得低於於1分分。Q1獎獎必要要條件件－最最低100分，，且各各項問問題評評分不不可低低於2分。。TQE獎必必要條條件－－符合合Q1必要要條件件及通通過TQE審核核。35MS-9000物物料管管理系系統必必要條條件4.1管管理責責任4.2物物料管管理系系統4.3檢檢討合合約/客戶戶接觸觸面4.4時時間表表系統統4.5文文件控控制4.6採採購轉轉包商商管理理4.8產產品驗驗證與與追蹤蹤4.9裝裝船4.10製製告告彈性性/存存貨管管理4.11檢檢驗驗測量量與測測試4.14糾糾正正與防防範4.15處處理理、存存放、、包裝裝和交交貨4.15.2處處理理4.15.3存存放放4.15.4包包裝裝4.15.6交交貨貨4.16物物料料記錄錄的與與控制制4.17物物料料內部部審核核4.18訓訓練練4.20統統計計方法法36SupplierDeliveryPerformance協力廠廠商交交貨實實績CriteriaASNAchievement:30%Timeliness:20%ShippingDiscrepancy:20%Overshipment:5%Packaging:15%ProblemReport:10%37執行SixSigma的的現況況2000年年開始始推廣廣SixSigma黑黑帶訓訓練開開始2001年年計畫畫開始始上課課並執執行2002現現況:黑帶人人數:2人執執行專專案5個綠黑人人數:53人執執行專專案14個個節省金金額:U$2,000/專案案38通用物物流管管理系系統39進口零零件來來源，，訂購購及包包裝方方式JapanSuzukiProntoUSIEOU204/J1414Directshipparts3.0Engine2.0/3.0T/MMexicoChihuahuaEng.2.0JapanMazadaC206EIIU204JapanJatco2.5AutoT/MEuropeIEOCD132HuppertzHBuildingCD132RGLCoughlinPXPWeeklyShipmentTransitTime51Days(Including16DaysFloat)iPXPWeeklyShipmentTransitTime46DaysLotWeeklyShipmentTransitTime10DaysPXPWeeklyShipmentTransitTime10DaysFordLoHoPlant40PartByPart訂購(Metrostar)批量訂訂購(其他他車種種Mazda,SuzukiandFordU204)以車型型車種種別以以批量量訂購購KDLotOrderByMSC.Lot國外供供應商商KDSource全球工工程發發行系系統WERS通用物物流管管理系系統CMMS供應商商資訊訊系統統SOLMIS供應商商訂單發發送方方式41BridgeInterfaceBetweenCorporate&LocalSystemNewModuleToBeDevelopedCorporateSystemExistingLocalSystemCMMS3-CD132PartUsage-VBOMWIPSATPSourcingSOLMISTradingCompanyUSSupplierMailboxFLHLocalSupplierRelease(CIF830/862)ASN(CIF856)VISMailboxEuropeanSystem-------------------------MSC→→EOC→→SFIEXCELFileDaily/MonthlyVehicleScheduleCatCodetoEOCForecast/Offline/OrderLine-upAccountsPayableMailboxReceipt(1-32)ActualPriceApprovedToolingDataReceiptActualPriceApprovedToolingDataPANDAMailboxUnitCostFAPCCommittedToolingDataICSImportpartspricemark-upPriceLook-upPriceLook-upMailboxMultipleBridgesImportPartsCMMS3ASN(web-based)VehicleCostAccountingMQSeriesSourcingMSCtoSFIConversionMailboxMailboxMailboxEuropeanSupplier42TaiwanForecast/SchedulingFeedstoCMMS3TAIWANLOCALSYSTEM(VIS)CatCode/EOCTableKDLotEmergingMktsForecastProcessEmergingMktsSchedulingProcess------------------------GPAMSolveCumCountsCMMS3CatCodeToEOCFileCatCodeToEOCCatCodeForecastByPeriodSegmented/SequencedOrderLine-up@EOCDay0Prod(Offline)Body&AssyplusCaptiveSeq.OrderLine-up@EOCSFICountsTYDProdDay-1(Bridge3-43)SFIEOCDay0Offline&CaptiveSeqConfirmedOrderLine-upGPAMTableOpPlanforTaiwanEventTableforTaiwanMaterialForecast@SFIbydayEventTableOpPlan(Bridge3-43)(Bridge3-42)(Bridge3-44)EXCELFILE==========Daily&MonthlyVehicleSchedule43批量(LotKit)訂購與PartByPart訂購購與包裝PartsUsage/Pack12345A4B1C5D3E2PartsPack123456789101112A6B12C7D5E10最低包裝量最低訂購量44(CommonMaterialManagementSystem)主要功能產生物料清單單及單一零件件採購功能以以支援所有物物流作業。推展零件製造造計劃,生產產排程及安全全存貨計劃。。計算及發佈每每日/每週的的交貨通知給給供應商。提供即時的存存貨狀態和資資料驗證。管理各儲存區區的物流進/出轉移作業業。以條碼系統收收集零件使用用量。出貨程序的管管理。計算交易及存存貨價值並提提供存貨預算算的控制報表表。提供與供應商商及顧客間的的電訊雙向溝溝通。通用物流管理理系統(CMMS)45系統設置及導導入由福特歐洲製製程先導部門門主導總投資費用：：US$1,697,000福特六和公司司七名優秀員員工參與配合合導入計劃通用物流管理理系統46導入時程表通用物流管理理系統Feb.212000完成CMMS3系統連接FLH內部網路Feb.282000WERS與CMMS3PlantCodeFI1LF連結(BOM)May292000WIPS連接(PartsSourcing)Jun.012000核準BOM(BillOfMaterial)Jul.312000車輛需求及預測資料(Forecast&Order)的試送及確認Aug.142000完成零件交貨通知連接至供應商(SOLMIS~FLHASN)Dec.042000CMMS3FullProduction正式啟用及首次收料Jan.062001CD132(Metrostar)開始試裝Jun.042001CD132Job#1Dec312001完成其他車種本地零件之應用47PXPVSKDLOT成本本比較(Atmigration,normalizedFLHcosts)成本PerUnit(US$)CDW162(KD)CD132(PXP)PXP(B/W)KD防鏽/包裝Oiling/boxing$729$246$483海運費/陸運費Seafreight/landing6290(29)空運費Airfreight12(1)進口稅Duty1385979報廢Obsolescence1266存貨InventoryCarryingCost-44(44)人工ManpowerIncrease-67(67)設備折舊FacilityDepreciation&Others-7(7)合計TotalCostImpactPerUnit$941$521$42048競爭優勢國際觀－全球球化之物流系系統去執行全全球採購與物物料跟催，達達到全球化專專業分工與策策略聯盟之目目的。福特六六和為全亞洲洲與北美第一一個汽車裝配配廠導入CMMS3系系統(通用物物流管理系統統)的工廠。。CMMS3提提供最及時之之物料移動狀狀況及庫存狀狀況，結合福福特生產系統統同步化物流流與JIT之之物流管理之之精神。成本效益－存存貨水準更容容易控制與管管理，達到物物流成本極小小化之目標。。彈性化之生產產－以零件為為訂貨單位，，生產更具彈彈性化，使顧顧客滿意達到到極大化。全球IT資源源分享，減少少系統發展之之投資成本。。49拓展外銷商機機50C206L3PartsExportOperationTierra零件外銷東南南亞FMI(Indonesia)IPM:Mar2002Job1:Apr2002Volume:873Units/YFM(Malaysia)IPM:Sep.2000Job1:Mar.2001Volume:1,080Units/YFVL(Vietnam)IPM:Jan.2002Job1:Mar.2002Volume:1,860Units/YFMCP(Philippines)IPM:Sep2001Job1Feb2002Volume:3,698Units/YFSST(Thailand)IPM:Feb2002Job1:Mar2002Volume:2,400Units/Y51JapanS.AfricaTaiwanEuropePhilippinesMalaysiaVietnamPhilippinesTaiwanKDLotSupplierSupplyChainMapping策策略聯盟與與專業分工MaterialSourcesS.AfricaLotAssemblyLotAssemblyThailandMalaysiaLocalSuppliersLocalSuppliersLocalSuppliersLocalSuppliersLocalSuppliersPxPAssemblyKDLotsrequiredforMalaysiaandVietnamduetolowvolume,Lackoflocalsystemscapability,anddevelopingexperienceinAPxPenvironmentKoreaChina52謝謝各位539、静夜四无无邻，荒居居旧业贫。。。12月-2212月-22Thursday,December29,202210、雨雨中中黄黄叶叶树树，，灯灯下下白白头头人人。。。。14:33:4814:33:4814:3312/29/20222:33:48PM11、以我独独沈久，，愧君相相见频。。。12月-2214:33:4814:33Dec-2229-Dec-2212、故人江海别别，几度隔山山川。。14:33:4814:33:4814:33Thursday,December29,202213、乍乍见见翻翻疑疑梦梦，，相相悲悲各各问问年年。。。。12月月-2212月月-2214:33:4814:33:48December29,202214、他乡生白发发，旧国见青青山。。29十二月月20222:33:48下午14:33:4812月-2215、比比不不了了得得就就不不比比，，得得不不到到的的就就不不要要。。。。。十二二月月222:33下下午午12月月-2214:33December29,202216、行动动出成成果，，工作作出财财富。。。2022/12/2914:33:4814:33:4829December202217、做前，能能够