IMPROVING PRODUCTIVITY AND QUALITY THROUGH BETTER VISIBILITY. 4 th September 2012

Transcrição

1 IMPROVING PRODUCTIVITY AND QUALITY THROUGH BETTER VISIBILITY 4 th September 2012

2 AT ZEBRA TECHNOLOGIES, WE...

3 OUR STYLE

4 ZEBRA TECHNOLOGIES CORPORATION

5 ZEBRA LOCATION SOLUTIONS

6 MATERIAL REPLENISHMENT

7 MATERIAL REPLENISHMENT

8 LEAN MATERIAL REPLENISHMENT HIERARCHY Manual Kanban Eletrônico Cartão / caixas Kanban

9 FLEXIBLE MATERIAL REPLENISHMENT Key Challenges Excess inventory and safety stock cost and floor space Safety issues due to congestion Line stoppage due to part shortage Inefficient material processes and accountability Excess radio traffic Solution Software Material Call Material Flow Replenish Hardware Active RFID Barcode Scanners Mobile Devices Solution Features Automated pull systems Multiple flexible triggers Support for Lean principles Real-time work instruction and exception handling Manufacturing messaging Recorded work metrics Analytics capabilities

10 WITH FLEXIBLE MATERIAL REPLENISHMENT, YOU CAN... Optimize Inventory: With historical consumption data, you can find optimum levels of demand and inventory Otimizar o inventário: Com dados de consumo histórico, você pode encontrar níveis otimizados de demanda e estoques Support Multiple Triggers: Employ a pull system based upon your suppliers capabilities Apoiar vários triggers: Utilizar um sistema puxado em função da capacidade do seus fornecedores Eliminate Lost Calls: Lost Kanban cards or forgotten radio calls are replaced by operator assignments Increase Productivity: Generate a significant improvement in labor and equipment utilization Eliminar Chamadas Perdidas: Cartões Kanban perdidos ou chamadas de radio sem atender são substituídos por tarefas atribuidas aos operadores Aumento da Produtividade: Criar uma melhora significativa na utilização dos operadores e equipamentos

11 MATERIAL REPLENISHMENT CASE STUDY: TIER ONE TRANSMISSION SUPPLIER BEFORE Material Flow Replenishment Manual replenishment process AFTER Material Flow Replenishment Wireless replenishment process Excess inventory Reduced inventory carrying costs by $750,000 Underutilized labor force Labor productivity up 20% Underutilized equipment Equipment utilization up 30% Excess waste (movement) Frequent line-stoppages Lack of supply/demand visibility into internal and external supply One-third reduction in daily forklift trips Virtually eliminated line downtime due to parts shortages Improved plant floor demand visibility

12 ASSET VISIBILITY, TRACKING AND MANAGEMENT

13 When it Comes to Assets, Most Companies are In the Dark 13

14 VISIBILITY TECHNOLOGIES COME IN MANY FORMS Bar Code: Provides portal location, within a configured area, Indoors and outdoors (presence location), with direct view. Passive RFID: Provides portal location, within a configured area, Indoors and outdoors (presence location), without direct view, but stores more data than bar codes. Active RFID: Provides real-time location, within a configured area, indoors and outdoors (2 3m accuracy), without direct view. GPS: Provides real-time location outdoors, in any line-of-sight location (4 10m accuracy).

15 EXAMPLES OF TRACKABLE ASSETS Stamping racks Returnable containers Totes Components (parts / subassemblies) Material handling equipment Body-In-White and/or skids Cordless industrial tools Finished vehicles Racks para peças de estampagem Containers retornaveis Caixas Componentes (peças / preassemblagem) Equipamentos de movimentação de materiais Carrocerias e/ou skids Ferramentas industriais sem fio Veículos acabados 15

16 With Better Visibility You Can Increase Flexibility: Manufacture more vehicle models, with more options to suit consumer needs, on the same line Incrementar a Flexibilidade: Produzir mais modelos de veiculos, com mais opções para atender a demanda do mercado na mesma linha de produção. Increase Throughput: Build more vehicles with the same resources and better productivity Improve Financials: Reduce the working capital required to operate your plants Improve Quality: Less risk of damage to WIP parts and finished 16 vehicles Aumentar o Volume de Produção: Produzir mais veiculos com o mesmos recursos e melhor produtividade. Aumentar o Lucro: Reduzir o capital de giro para operar nas plantas. Aumentar a Qualidade: Diminuir o risgo de danificar as peças do WIP e dos veiculos acabados

17 RACKS AND CONTAINERS Key Challenges Accurate container counts and locations Resource Utilization Lack of history on missing containers Confirmation of receipt of all containers purchased Solution Software Container & Rack Tracking Hardware Barcode Passive RFID Active RFID Solution Features Visibility of all On-Site containers Automated or manual status change i.e. full vs. empty Initial and continuing fleet accountability through status and Ship To history

18 RACK AND CONTAINER CASE STUDY MAJOR OEM BEFORE Container and Rack Tracking No visibility to stored inventory Manual Search Process (hours) Lost / misplaced containers Containers used to store scrap parts Racks in repair were off the radar New racks ordered for new vehicle programs Extra racks / containers ordered AFTER Container and Rack Tracking Real time visibility to rack/container contents Automated search process (seconds) Location known; alerts activated Scrap accounted for more accurately Proper acknowledgement of repair volumes Racks from previous programs reused Active management of rack / container fleet sizes without incremental purchase Significant Waste Removed (Labor, Redeployed Rack Savings)

19 VEHICLE OFF-LINE AND CONTAINMENT Key Challenges Need for increased throughput in Off Line area as production rates increase. Improved visibility to rework areas / consistent handling to improve quality Increased velocity in ship yards and real time location of all vehicles Eliminate manual yard inventories Solution Enterprise Software Vehicle Tracking and Management (VTMS) Visibility Software (VSS) Technology Active RFID Passive RFID Barcode Mobile devices Solution Features Real time visibility to finished vehicles Rule based processing for Off Line area Quality containment Alerting

20 VEHICLE OFF-LINE AND CONTAINMENT CASE STUDY MAJOR OEM BEFORE Vehicle Tracking No visibility to off line vehicles AFTER Vehicle Tracking Real time location for all produced vehicles Excess inventory of in process vehicles Reduced WIP vehicles by 20% Manual process for yard inventory Poor containment of re-work vehicles No visibility to orders vehicles after of line High labor costs in off line Automated process for re-work based on work rules 100% containment of quality held vehicles Real time location of all orders Redeployed 8 headcount equivalents

21 IMPLEMENTING ZEBRA SOLUTIONS

22 ACHIEVING IMPLEMENTATION SUCCESS LEAN Manufacturing Concepts + Application and Integration of Real-Time Information Technology + Educated, Empowered Teams

23 SOLUTIONS STACK Enterprise Applications Zebra Execution Systems Custom ERP System Material Replenish Yard Mgmt Parts Tracking Rack Tracking XML RESTful Interface (2-way) ZEBRA LOCATION AND MESSAGING PLATFORM Zebra Asset Visibility Zebra Device Interface

24 SAMPLE OF OUR AUTOMOTIVE AND AEROSPACE CUSTOMERS 24

25 ZEBRA TECHNOLOGIES IS THE VISIBILITY EXPERT We have over ten years of experience and over 200 implementations in RFID; 30+ years in bar code We use the right technology for the right application Temos 10 anos de experiência em soluções Rfid, com mais de 200 implementações; e + de 30 anos em soluções com códigos de barras. Usamos a tecnologia certa para cada tipo de aplicação. Once installed, our solutions operate for years Quando instaladas as nossas soluções operam por muitos anos. Our solutions typically provide ROI payback within 6 12 months Tipicamente, as nossas soluções tem um retorno sobre o investimento de 6 12 meses. 25

26 Obrigado