BOS Production meets IT - TALC · IT Competence Center Production ... BOS GmbH & Co. KG Transfer...

BOS

Production meets IT

IT CC Production / Digitalisation (IT-PD)

IT Competence Center Production / Digitalisation I 21. September 2017

BOS GmbH & Co. KG Transfer and copy solely with prior written consent of BOS 2

Content

• Introduction of BOS company

• Customer and initial business requirements

• Roof system … new product

• Project organisation

• New team IT-PD department

• System architecture

• PRODNET

• Standards for data collection

• JIS mode production

• JIS strategy with sequencing within production has been changed

• SAP interface

• BATCH mode production

• Q-Gate process with sequencing in IL

• Challenges and experiences

• Future & next steps



The BOS Group – a global automotive supplier …



International Group - family held

Founded in 1910

Grown by innovation and internationalization

Leading manufacturer of kinematics, mechatronics and plastics systems for European,

American and Asian carmakers

In 2017: 850m Euro sales I over 7.000 employees I 20 locations in 12 countries on 3 continents

Consequent “Best Cost Country“ strategy with global BOS production system and localization

of components

Customer and vehicle specific product solutions from standardized component kits

Product development in close cooperation with customers world-wide on site

The BOS Group - Global Technology and Cost Leadership



Luggage Cover Systems

Arm Rests I Upholstery Parts

Door Handle Systems

Sun Protection Systems

Cargo Management

Carrier Systems

Panoramic Roof Systems

Safety Restraining Nets

Plastic in the Engine

Compartment

Mechatronics

The BOS Group -

Innovative kinematics I mechatronics I plastics systems

5

The BOS Group defines the state of the art in various product fields of the vehicle.



The BOS Group -

Customers

6

Dräxlmaier

DRAC

DS

Evobus

Faurecia

FAW-VW / Audi

Fiat

Ford

GAC

GAC-FCA

Geely

GM

Great Wall

Grupo Antolin

Hayashi Telempu

Holden

Honda

Howa Textile

Hyundai

Aisin

Alfa Romeo

Audi

Autoneum

Avtovaz I Lada

BBA

BBAC

Bentley

BMW

Borgers

CAF

Changan

Chery

Chevrolet

Chongqin Changpeng

Chrysler

Citroën

CJLR

Dacia

Daimler

IAC

Inalfa RS

Infiniti

Inteva

JAC

Jaguar

JCI

John Deere

Kasai

Kia

Lancia

Land Rover

Lear

Lexus

Lifan

Lynk&Co.

Magna

MAN

Maruti-Suzuki

Maserati

Mazda

Mini

Neoplan

Nissan

Opel

Peugeot

Plastic Omnium

Plexicor

Porsche

Qoros

Renault

Renault Samsung

Renault Trucks

Rolls Royce

Seat

SAIC GM

SAIC VW

Skoda

Smart

SMP

SsangYong

Subaru

Tesla

Toyota

Toyota Boshoku

TS Tech

Vauxhall

Visteon

Volkswagen

Volvo

Webasto Donghee

Webasto

Yachiyo

Yanfeng Visteon



Roof Systems -> The very first Contact

SAP (BOS MOS BOS WW)

???

- Production sequence

- Roof type (F-01; F-02)

- Customer color

- BOS endproduct number

- Laufende Nummer (i.O Teile)

- BMW partnumber

- JIS Sequence number

- Order Number

- Part family

- Vehicle identification number

- Teile Lebenslauf LL 99

- Reorder process !!! (Prio1)

Line

PL

C

PL

C

PL

C

PL

C

PL

C

PL

C

Master PLC

EOL

SQL

- Booking scrap

- Booking finished part with BOS

unique number and serial number

- Check of sequence

- Label Printing 1:1.Dachtyp (F-01; F-02; F-10)

2.Teile Lebenslauf LL 99

3.Produktionsdatum und Uhrzeit

4.Seriennummer

(Laufendenummer der

Produktion)

5.Webastonummer inkl.

Änderungsindex 1724902G

6.Farbbezeichnung

7.Barcode:Typ DATA Matrix

8.Barcode Typ 2 of 5 (ITF)

- Label Printing 2:

- IFF Portal - EDI JIS Call off - Delivery (ASN) via EDI

EDI (BMW BOS MOS)

*.CSV Import from SQL



Roof Systems -> New Product Field –> New Challenges

▪ Until now

– Production in area of interior components

– Mainly batch production

– Production was mainly manual hand work

– Paper based

▪ From now on

– Roof systems in area of exterior

– Safety critical production

– JIS as new process methodology (Production, logistic, …)

– Process Automation

– Data Traceability (Machine, Process, Quality)

– Data Visualisation (Reports, Andon, …)



Conclusion – IT Requirements and Aims

▪ System

– Customizable

– Modular / Scalable

– High availability

– Certified SAP Connector

– Setups must be reusable

– System supplier must have high experience - Cooperation at eye level

– System supplier must be able to grant world wide support

▪ Process Control

– JIS (Sequencing)

– Q-Gate

– Rework

– Validation / Checks



Conclusion - IT Requirements and Aims

▪ Data Traceability and Visualisation

– Pre-Assembly and main production line

– Standards for processes and reports

– Automated processes (with possibilities for manual interaction)

▪ Global IT Team

– Requirements and specifications

– Implementation

– Support



New IT Team -> CC Production / Digitalization

▪ Targets

– Global team

• Think global – act local

– Core team which is BOS IT

• Main contact for any questions / tasks regarding “Basic IT Infrastructure” and MES

• Worldwide implementation of system

– Standardization of relevant core processes

• Concentration of process knowledge

• Support for existing processes



- Controlled and secured communication between office and production network

- Controlled and secured remote access to production machines for suppliers and service partners

Basic IT Infrastructure

- Standardized system - Data traceability - Support of BOS standard

processes- JIS production - Batch production

- SAP gateway

Intelligence Layer /

Roof Production

Fields of Activity

Digitalization of BOS

Production

- Information/data exchange between any systems

- Harmonizing the „systemlandscape“ for production systems

- Inter disciplinair projects



PRODNET – Production Network

▪ PRODNET

• Secured IT infrastructure

▪ Remote access for suppliers

• Secured remote connection

for service partners to their

machines



BOS data collection and SAP standards

▪ BOS \ OPC data collection guideline

• Flag system

• Production start

• Finished production

• Process data collection

• Bidirectional communication

• Service message

▪ SAP interface standards

• JIS demands

• BATCH demands

• Start Of Production

• End Of Production



JIS model – original concept

▪ SAP interface

• JIS orders

• Status synchronization

▪ Production

• JIS queue for production



JIS ORDERS

JIS STATUS



JIS model – current process

▪ SAP interface

• JIS orders

• Status synchronization

▪ Production

• BATCH queue for production


▪ Q-Gate

• Quality inspection via DCIx

• JIS – Packaging

• Packaging via DCIx

• Secured packaging

• Secured data traceability



BATCH process

▪ SAP interface

• One direction communication

• Backflush via HU-label

▪ Production

• One direction communication

• BATCH demands via DCIx report



▪ Q-Gate

• Quality inspection via DCIx

• Quality traceability

• Box content check



Challenges

▪ New processes -> Change of thinking

▪ Different level of knowledge and experience

• Communication - Especially in international context

• Easy to understand – difficult to manage

• Merging global and local targets

• A lot of stakeholders

• Customer

• Suppliers

• BOS departments

• Global Specifications and documentation

• Change management

• Count of needed PLCs

• Process changes



Foresight

▪ Working on standardisation of processes

▪ With focus on business needs

▪ Reports have to improve production transparency

▪ Right information for right people in time

▪ Focus on customers

▪ The benefit is recognized

• First request to support other production processes



BOS Roof Systems: Launches on three continents

2017 2018 2019 2020

HU-MOS

November

MX-IRA

April

CN-SHE

AugustHU-MOS

September

HU-MOS

November

MX-IRA

August

HU-MOS

July

HU-MOS

July

HU-MOS

March

MX-IRA

AugustCN-SHE

May

CN-TAI

March.

CN-TAI

April

HU-MOS

June



Thank you for your attention.

BOS GmbH & Co. KG

International Headquarters Stuttgart

Ernst-Heinkel-Straße 2

73760 Ostfildern

Tel. +49-(0)711-9360-0

Fax +49-(0)711-9360-1150

www.bos.de

[email protected]

BOS Production meets IT - TALC · IT Competence Center Production ... BOS GmbH & Co. KG Transfer...

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Transcript of BOS Production meets IT - TALC · IT Competence Center Production ... BOS GmbH & Co. KG Transfer...