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Sequencing Center for OEM

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jdavidgreen007

The document outlines plans for managing off-site warehousing and sequencing assemblies for GM assembly plants. It describes setting up linear kitting lines to sequence parts and subassemblies for delivery to plants just-in-time based on their broadcasts. It aims to enable plants to operate with lower inventories and higher turns by controlling quality issues and rapid responses from the off-site location.

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Business Concept #1 thru #5 Off Site Facility #6 thru #11 Costing Model #12 thru #X TPS – GM Sequencing Project
TPS - GM Sequencing Project TPS Off Site Central Warehouse GM Receiving and Assembly Line Distribution Objectives: Manage off site Central warehousing and regional distribution center(s) Sequence Assemblies, Subassemblies an/or Kits to GM Assembly Plants per JIT Broadcast at TPS off site location(s). Enable GM Assembly Plant(s) to operate successfully with lower inventory levels and higher inventory turns Control non-conforming material and supply base quality issues with rapid break points response, certified sorting and/or 3rd party containment at TPS off site location(s). Manage disposable and returnable container and dunnage requirements at TPS off site location(s) Rack 1 Rack 2 Rack 3 C B A C B A C B A JIT ATV Kits Station 1 Kits Station 2 Kits Station 3 Receiving Door Delivery Schedule
Manage Off Site Central Warehousing (w/ Multiple Linear Kitting Lines) Linear Kitting Line #1 Linear Kitting Line #2 Linear Kitting Line #3 Warehouse Tugger Service Trucking Service GM Suppliers Broadcast 1 Line 1 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 1 Kit Station 2 F1 E1 D1 F2 E2 D3 D2 Line 2 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 2 Kit Station 2 F1 E1 D1 F2 E2 D3 D2 Line 3 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 3 Kit Station 2 F1 E1 D F2 E2 D3 D2 X GM Broadcast Signal Kanban Fork Lift Service
Integrated Kitting and Sub assembly Line (Linear Kitting Line) w/ (U-shape flexible cell) LOAD ENTRY to Sub assembly Line Linear Kitting Line 1 4 2 3 5 6 7 Typical ‘U-shaped’ sub-assembly Cell 2 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Kit Station 2 F1 E1 D1 F2 E2 D3 D2
3 Enable GM Assembly Plant(s) Operate successfully with lower inventory levels higher inventory turns Station #1 GM Assembly Line Station #2 Station #3 GM Assembly Plants Kitting & Sequencing Container Delivery TPS
Control Non-conforming material Off Site @ TPS Warehousing 4 Linear Kitting Line #3 Warehouse Trucking Service GM PR&R’d Supplier PR&R Certified Stock Recurrent Non conformances Rapid Break Point TPS Control Line 3 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 3 Kit Station 2 F1 E1 D F2 E2 D3 D2 Fork Lift Service Quarantine Inventory & WIP @ TPS facility Manage 3 rd party containment if required 100% Certify
Manage Containers and Dunnage Disposable and Returnable 5 Disposable &/or Scrap Inspect & Clean Wash Finished Goods Container Management Process TPS Warehouse Suppliers GM Assembly Plants Kitting & Sequencing Containers Bulk Containers Tracking System 1 2 3 5 5 Re-order 6 No Yes Repair
Off site Plant Layout 6 Supermarket Shipping Fork Lift Service Fork Lift Service X Tugger Service Linear Kitting Line #1 Linear Kitting Line #1 Linear Kitting Line #1 Quarantine And Certification Packaging and Dunnage Control Sequencing Tugger Service Area TPS Office Supplier Receiving Doors GM Shipping Doors
Off site Plant Supermarket Layout 7 Racking Layout Bulk Material Storrage
Off site Plant - Tugger System 8 Dolly Exchange Tugger Vehicle Sequencing Line Racking 180’ turn inside 10 Feet !
Off site Plant – Kanban Delivery System 9 Kitting Line Rack 1 Rack 2 Rack 3 C B A C B A C B A C B A Central Supermarket Storage X X Kanban Card Delivery Route X Empty Containers X Standardized routes delivering small containers on a frequent schedule (once per hour or less). More frequent deliveries lower material inventory at operations. 12 1 2 3 Signal alerts time for Kanban cards to be collected from posts. A-107 A-108
Off site Plant – Dolly Delivery System 10 Dolly Exchange Empty Full Full Full Full Full Full Part: Adjuster Part No: 9981427 Std. Pack: 90 Min: 1 Max: 3 Stack: 3 High Part: Pan Part No: 4563273 Std. Pack: 75 Min: 1 Max: 3 Stack: 3 High Full Full Route driver delivers dolly & full container based on signal. Full Empty Empty dolly signals replenishment. Operator pushes out empty dolly & container then pulls next dolly into position. A-108
Off site Plant – Plan for Every Part 11 PFEP Step 1: Begin to populate the PFEP spreadsheet Row, Part Name, Part # & Color, Supplier, Std Pack Container info – dimensions, returnable or expendable etc. Step 2: Add usage data Avg weekly use from the actual GM customer schedule Station # and whether it’s a bulk or supermarket part Step 3: Line Side Calculations Assumes Min of 2 hours / Max of 4 hours Calculates requirements and rounds up to Standard Pack Step 4: Storage Calculations How many hours on hand (based on receiving schedule) How S/M spots required? S/M Containers per skid? Step 5: SORT ! Separate Bulk from Supermarket Components Step 6: Apply the Tool Layout Bulk Storage to actual utilization Layout Supermarket correctly Institute Kanban Max Line Side Column = # of Kanbans Calculate Warehouse Space requirements : Based on PFEP Input data from GM Customer Releases Based on number of GM stations to be Sequenced from Kitting Lines at TPS Based on present Actual Shipping Schedules from Suppliers Based on rate of Kitting by TPS operators Based on Number of Receiving/Shipping Docks available. 8 15 48 Exp   135 Capro   L0033115AD,01 Cable ASM - Latch Synch, 2RS, 60% LH 2 10 15 12 R   24 BAE   L0033100AF,01 Latch ASM - Floor, O/B, 2RS, 40% RH, 920 2 10 15 12 R   15 BAE   L0033099AF,01 Latch ASM - Floor, I/B, 2RS, 60% LH, 920 2 10 15 12 R   24 BAE   L0033097AF,01 Latch ASM - Floor, O/B, 2RS, 60% LH, 920 2 H W L Container Size Cntnr Retrn or Exp Std. Cntr Std Pck Supplier Color Code PDM # Part Description Row Supplier/Container   Part Information

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Sequencing Center for OEM

  • 1. Business Concept #1 thru #5 Off Site Facility #6 thru #11 Costing Model #12 thru #X TPS – GM Sequencing Project
  • 2. TPS - GM Sequencing Project TPS Off Site Central Warehouse GM Receiving and Assembly Line Distribution Objectives: Manage off site Central warehousing and regional distribution center(s) Sequence Assemblies, Subassemblies an/or Kits to GM Assembly Plants per JIT Broadcast at TPS off site location(s). Enable GM Assembly Plant(s) to operate successfully with lower inventory levels and higher inventory turns Control non-conforming material and supply base quality issues with rapid break points response, certified sorting and/or 3rd party containment at TPS off site location(s). Manage disposable and returnable container and dunnage requirements at TPS off site location(s) Rack 1 Rack 2 Rack 3 C B A C B A C B A JIT ATV Kits Station 1 Kits Station 2 Kits Station 3 Receiving Door Delivery Schedule
  • 3. Manage Off Site Central Warehousing (w/ Multiple Linear Kitting Lines) Linear Kitting Line #1 Linear Kitting Line #2 Linear Kitting Line #3 Warehouse Tugger Service Trucking Service GM Suppliers Broadcast 1 Line 1 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 1 Kit Station 2 F1 E1 D1 F2 E2 D3 D2 Line 2 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 2 Kit Station 2 F1 E1 D1 F2 E2 D3 D2 Line 3 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 3 Kit Station 2 F1 E1 D F2 E2 D3 D2 X GM Broadcast Signal Kanban Fork Lift Service
  • 4. Integrated Kitting and Sub assembly Line (Linear Kitting Line) w/ (U-shape flexible cell) LOAD ENTRY to Sub assembly Line Linear Kitting Line 1 4 2 3 5 6 7 Typical ‘U-shaped’ sub-assembly Cell 2 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Kit Station 2 F1 E1 D1 F2 E2 D3 D2
  • 5. 3 Enable GM Assembly Plant(s) Operate successfully with lower inventory levels higher inventory turns Station #1 GM Assembly Line Station #2 Station #3 GM Assembly Plants Kitting & Sequencing Container Delivery TPS
  • 6. Control Non-conforming material Off Site @ TPS Warehousing 4 Linear Kitting Line #3 Warehouse Trucking Service GM PR&R’d Supplier PR&R Certified Stock Recurrent Non conformances Rapid Break Point TPS Control Line 3 Kit Station 1 C1 B1 A1 C2 B2 A3 A2 Line 3 Kit Station 2 F1 E1 D F2 E2 D3 D2 Fork Lift Service Quarantine Inventory & WIP @ TPS facility Manage 3 rd party containment if required 100% Certify
  • 7. Manage Containers and Dunnage Disposable and Returnable 5 Disposable &/or Scrap Inspect & Clean Wash Finished Goods Container Management Process TPS Warehouse Suppliers GM Assembly Plants Kitting & Sequencing Containers Bulk Containers Tracking System 1 2 3 5 5 Re-order 6 No Yes Repair
  • 8. Off site Plant Layout 6 Supermarket Shipping Fork Lift Service Fork Lift Service X Tugger Service Linear Kitting Line #1 Linear Kitting Line #1 Linear Kitting Line #1 Quarantine And Certification Packaging and Dunnage Control Sequencing Tugger Service Area TPS Office Supplier Receiving Doors GM Shipping Doors
  • 9. Off site Plant Supermarket Layout 7 Racking Layout Bulk Material Storrage
  • 10. Off site Plant - Tugger System 8 Dolly Exchange Tugger Vehicle Sequencing Line Racking 180’ turn inside 10 Feet !
  • 11. Off site Plant – Kanban Delivery System 9 Kitting Line Rack 1 Rack 2 Rack 3 C B A C B A C B A C B A Central Supermarket Storage X X Kanban Card Delivery Route X Empty Containers X Standardized routes delivering small containers on a frequent schedule (once per hour or less). More frequent deliveries lower material inventory at operations. 12 1 2 3 Signal alerts time for Kanban cards to be collected from posts. A-107 A-108
  • 12. Off site Plant – Dolly Delivery System 10 Dolly Exchange Empty Full Full Full Full Full Full Part: Adjuster Part No: 9981427 Std. Pack: 90 Min: 1 Max: 3 Stack: 3 High Part: Pan Part No: 4563273 Std. Pack: 75 Min: 1 Max: 3 Stack: 3 High Full Full Route driver delivers dolly & full container based on signal. Full Empty Empty dolly signals replenishment. Operator pushes out empty dolly & container then pulls next dolly into position. A-108
  • 13. Off site Plant – Plan for Every Part 11 PFEP Step 1: Begin to populate the PFEP spreadsheet Row, Part Name, Part # & Color, Supplier, Std Pack Container info – dimensions, returnable or expendable etc. Step 2: Add usage data Avg weekly use from the actual GM customer schedule Station # and whether it’s a bulk or supermarket part Step 3: Line Side Calculations Assumes Min of 2 hours / Max of 4 hours Calculates requirements and rounds up to Standard Pack Step 4: Storage Calculations How many hours on hand (based on receiving schedule) How S/M spots required? S/M Containers per skid? Step 5: SORT ! Separate Bulk from Supermarket Components Step 6: Apply the Tool Layout Bulk Storage to actual utilization Layout Supermarket correctly Institute Kanban Max Line Side Column = # of Kanbans Calculate Warehouse Space requirements : Based on PFEP Input data from GM Customer Releases Based on number of GM stations to be Sequenced from Kitting Lines at TPS Based on present Actual Shipping Schedules from Suppliers Based on rate of Kitting by TPS operators Based on Number of Receiving/Shipping Docks available. 8 15 48 Exp   135 Capro   L0033115AD,01 Cable ASM - Latch Synch, 2RS, 60% LH 2 10 15 12 R   24 BAE   L0033100AF,01 Latch ASM - Floor, O/B, 2RS, 40% RH, 920 2 10 15 12 R   15 BAE   L0033099AF,01 Latch ASM - Floor, I/B, 2RS, 60% LH, 920 2 10 15 12 R   24 BAE   L0033097AF,01 Latch ASM - Floor, O/B, 2RS, 60% LH, 920 2 H W L Container Size Cntnr Retrn or Exp Std. Cntr Std Pck Supplier Color Code PDM # Part Description Row Supplier/Container   Part Information