traceability inventory
DESCRIPTION
tracebility inventoryTRANSCRIPT
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Transmission Traceability & Shipment ControlMr. Peter Itoa, IT Manager, GETRAG FORD Trasmissions Slovakia, s.r.o.
Logistic Conference 2015Bratislava, March 18, 2015
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business Requirements
3. Project Definition
4. Technical Overview
5. Deliverables
2
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business Requirements
3. Project Definition
4. Technical Overview
5. Deliverables
3
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Key Figures
FormationFebruary 1, 2001 as 50:50 joint venture of GETRAG and Ford of Europe
Development and productionof transmissions
HeadquartersCologne
Production plantsCologne
Halewood
Bordeaux
Kechnec
GETRAG FORD Transmissions
44
Sales
1.16 billion
World Production
1.5 million transmissions
Employees
4,400
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Full Service Systems Supplier
5
Our service range covers the entire process chain:
including all engineering services and spare parts
Idea Concept PrototypingVehicle
integration
Mass
productionValidation
GETRAG FORD Transmissions
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GETRAG worldwide
March 23, 2015Company Presentation6
24 locations worldwide in Europe, North America and Asia
14 individual companies
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Key Facts 2013
March 23, 2015Company Presentation
GETRAG in figures
3.2 Billion EUR 3.9 Million transmissions
Sales Global production Employees
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13,250
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Plant Kechnec
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Production of dual clutch transmissions
(GETRAG PowerShift)
Established
2005
mid 2007 (start of mass production)
Employees
1000
Built capacity
265k units / year
- planned extension 400k
GETRAG FORD Transmissions Slovakia s.r.o.
Site Management
Wes Jacklin
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Kechnec
Key features:
Torque Range up to 450 Nm
2 variants:
MPS6 (3 shaft design)
for C- and CD-car
SPS6 (short 2x2 shaft design)
for CD-car and SUV
AWD capable
Products: Powershift Transmissions 6DCT450
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business Requirements
3. Project Definition
4. Technical Overview
5. Deliverables
10
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business requirements
3. Project definition
4. Technical Overview
5. Deliverables
11
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Problem #1 - TRACEABILITY
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Powershift: 37 500 m2
LSC: 10 152 m2
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Problem #2 - QUALITY
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Business Issues ...Why has been project established?
Insufficient quality control tracking of built transmissions
Missing posibility of unique tracking of each produced piece
Only transmission type & quantity
Inventory inaccuracy
Undesired stock-taking differences
Negative influence of human factor
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The main objective
Prevent the export of any transmission that can have a quality problem
Inventory accuracy
IT system supporting "STOP SHIPMENT" process
Precise control of each produced piece
Identify & track the causes that led to the eventual qualitative deficiency
Minimum production and logistics downtime for initial serialization of inventory at GoLive
Business Need = Project Goals
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business requirements
3. Project definition
4. Technical Overview
5. Deliverables
17
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business requirements
3. Project definition
4. Technical Overview
5. Deliverables
18
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Requestor
Plant TOP Management
Project Sponsor
Senior Manager Manufacturing Engineering
Project Leader
Local Plant IT employee
Business processes overview
IT expertise
Project leadership potential
Project Name
Transmission Shipment Control (TSC)
Project Management Methodology
PRINCE2TM
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TOP
DOWN
Project Definition & Potencial
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Kechnec team:Projekt leader: 1person (IT)
Logistics: 3 persons
Production: 1 person
Quality: 2 persons
Engineering: 2 persons
Local IT: 2 persons
Central IT: 1 person
Suppliers:HP
Quantum
Project Team
Project Steering Committee: Kechnec Plant
GETRAG Central IT
HP
Quantum
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Project timing
1 year (November 2011 December 2012)
Project set up with
German HP consultants/ developers working remotely
Team from Quantum Information Systems Solutions Inc.
Local Slovak customer team (Business and IT)
Regular status audios and web-based workshops were held to ensure the quality of
the deliverables
During Go-live the entire team worked onsite in the Kechnec plant to
support the initial serialization of the complete transmission inventory
ensure a smooth go live of all new functions
Delivery approach
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business requirements
3. Project definition
4. Technical Overview
5. Deliverables
22
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business requirements
3. Project definition
4. Technical Overview
5. Deliverables
23
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Available IT Landscape
Assembly End of Line Testing Repair/Repack/Garage Logistics storages Shipping
S/N HU+
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TS
C
inte
rfa
ces
1
2
3
5 4
6ATC
inte
rfac
e
-Net -Net
Before Now
Derivate A
Derivate B
As
sy->
EO
L->
Ware
ho
use->
Sh
ipp
ing
->C
usto
mer
Serial #
Batch
processingUnique
Identification
&
blocking
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The productive SAP ERP ECC 6.0 functionality has been enhanced by implementation of:
serial number & handling unit management
warehouse management for shipping stock
New SAP processes for Logistics have been designed in order to easily: handle stock transfers
picking
labeling
loading using radio-frequency scanner devices
The existing interface between Q-Net and SAP has been reengineered and new
scenarios have been developed in order to support: automatic confirmations
stock transfers
packing
reflash
quality blocks
Delivery approach (2) (technical view)
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business requirements
3. Project definition
4. Technical Overview
5. Deliverables
28
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Agenda
1. GETRAG FORD Transmissions Slovakia, s.r.o. Introduction
2. Business requirements
3. Project definition
4. Technical Overview
5. Deliverables
29
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TSC Solution Highlights
Full traceability
Unique identification of each single transmission in SAP and Q-Net based on serial number
No SAP movement of transmission without identification by serial number
Controlled quality status of each unique transmission
No shipment of NOK/Blocked transmission
Minimum manual data input
Hand Held Scanners data input & Automatic data exchange to reduce human failure
Agility
Flexible system configuration to easily allow enhancements and roll-outs
Full flow control of each single transmission
from ASSEMBLY to the TRUCK
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TSC Practical Deliverables & Business Benefits
Blocking process
Improved, speeded up and related to single serial number
Increase of transmission stock accuracy
0 inventory difference during 2012&2013 annual physical inventory
Transmission Warehouse Management
Immediate transmission localization in LSC
Enhanced transmission picking and shipment
FIFO
Transmission twins discovering
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Success Stories of Kechnec TSC Solution
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HP NEWSLETTER: Success Story in GETRAG
Transmission Shipment Control in SAP ECC 6.0 and Q-Net
TSC roll-out in GETRAG Mexico
Irapuato plant, Base on Kechnec pilot, GoLive: 07/2014
TSC roll-out in GETRAG Germany
Neunstein plant , GoLive: 12/2014
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Thank you for your attention