Ford Otosan Smart Supply Chain Projects ODETTE 2017 ...€¦ · commercial vehicle exports Market...
Transcript of Ford Otosan Smart Supply Chain Projects ODETTE 2017 ...€¦ · commercial vehicle exports Market...
ODETTE 2017
RECAI ISIKTAS – LOGISTICS MANAGER
Ford Otosan – MPL 4.0 Smart Supply Chain Projects
Recai Işıktaş – Logistics Manager
AGENDA 2
Turkish Automotive Industry
Ford Otosan Overview
Ford Otosan MP&L 2016 Innovation Projects
Packaging Test Center
Smart Weighing System
Ford Otosan Digital Vision
Connected Supply Chain and RFID
EUROPEAN & TURKISH AUTOMOTIVE INDUSTRY 3
0.0%
1.0%
2.0%
3.0%
4.0%
5.0%
6.0%
7.0%
8.0%
15,000
16,000
17,000
18,000
19,000
20,000
21,000
22,000
23,000
24,000
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Production Trend of Turkey (*Total Auto Industry)
Europe Turkish Production Share
X 1000
2009
Global
Crisis
TURKISH AUTOMOTIVE INDUSTRY 4
0%
5%
10%
15%
20%
25%
30%
0
200,000
400,000
600,000
800,000
1,000,000
1,200,000
1,400,000
1,600,000
1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016
Turkey & Ford Otosan Production
OTHER FO RATIO
2001
Crisis in
Turkey
FO Gölcük
Plant
opened in
2001
2009
Global
Crisis
FO started to
export Transit
Connect to US
FO Yeniköy
Plant opened in
2014
5
6
Key Indicators 2016
Koç Group
Ford Motor
Co.
Free Float
Ford Otosan
18%
41% 41%
Paid-in Capital: TL 350,910,000
Revenues $6.1 billion
Export Revenues $3.8 billion
EBITDA $519 million
Profit Before Tax $321 million
Net Profit $317 million
ROE 30.2%
EBITDA margin 8.6%
Annual Production Capacity 415,000
Gölcük (Transit & Custom) 290,000
Yeniköy (Courier) 110,000
İnönü (Cargo) 15,000
Total Employees 10,261
Blue Collar 7,561
White Collar 2,700
COMPANY PROFILE
PLANTS AND FACILITIES 7
Black Sea
İstanbul PDC
Honda Hyundai
Toyota
Tofaş-Fiat Renault
Kocaeli Plant
Sea of Marmara
Inonu Plant
●Eskisehir
●Bursa
●İstanbul ●Kocaeli
●Sakarya
Sancaktepe Engineering Center- 2015
Industrial Center of Turkey: Marmara Region
İnönü Plant - 1982
Sancaktepe Parts Distribution Center- 1998
Yeniköy Plant - 2014
Gölcük Plant - 2001
KEY PLAYER IN FORD MOTOR COMPANY 8
Güçlü satış
performansı
En büyük ticari araç
üretim merkezi
Ar-Ge ve
mühendislik gücü
Robust sales
performance
Leading
manufacturing
hub
Engineering and
R&D power
Global hub for Cargo heavy trucks and related powertrains
Global support for Light Commercial Vehicle Development
Global support for Diesel Powertrain Engineering
Highest commercial vehicle market share of Ford in Europe
Among Ford’s top 5 markets in Europe (Britain, Ireland,
Hungary, Turkey, Finland)
Lead manufacturing plant of Ford Transit globally
Single source of Ford Transit Custom & Tourneo Custom
Single source of Ford Transit Courier & Tourneo Courier
One of the two production centers globally for Ford Cargo
heavy trucks
FORD OTOSAN AT A GLANCE 9
Liderlik ve ölçek
avantajları
Strong value
contribution
Pioneer of
Turkish
automotive
Leadership and
scale
First Turkish passenger car Anadol (1966)
Turkey’s first domestic diesel engine Erk (1986)
Turkey’s first private R&D center in automotive (1961)
First export of Turkish automotive to the US (2009)
Turkey’s export leader
Turkey’s 2nd largest industrial enterprise
Highest employment in Turkish automotive
22% of Turkey’s total
automotive production
62% of Turkey’s total
commercial vehicle production
65% of Turkey’s total
commercial vehicle exports
Market leader in Turkish commercial vehicle industry with 30%
share
Widest product range in Turkish automotive
Highest installed production capacity in Turkish automotive
PRODUCTS, CAPACITY AND PRODUCTION
10
Production at 2014
244.000 units
Production at 2015
334.000 units
Production at 2016
333.000 units
Production Plan of 2017
359.000 units
11
TURKEY’S EXPORT CHAMPION
Export breakdown (units)
W. Europe 13%
UK 31% Germany 18%
France 8%
Spain 6%
Belgium 3%
Italy 7%
Other 5%
2016
E. Europe 9%
Turkey’s CV exports
Ford Otosan
65%
2016
12
FORD IS EUROPE’S BEST-SELLING CV BRAND
Jan YoY growth
in Ford’s CV sales
Ford Otosan’s share in
Ford Europe’s Transit Sales
2011 2012 2013 2014 2015 2016 2017
Ford’s European CV Market Share
#7 #6
#3 #1 #7
#1
8.5% 10.0% 11.5% 12.6%
8.6%
13.2% 14.0%
#1
13
FORD OTOSAN’S 2016 MP&L
INNOVATION PROJECTS
PACKAGING TEST CENTER
SMART WEIGHING SYSTEM
14 1) PACKAGING TEST CENTER
1) PACKAGING TEST CENTER- SAMPLE PACKAGING TEST
Vibration and Road Simulation Tests
15
This test method is used for determining the ability of packaging to withstand the
vibration during transport and the dynamic compression forces resulting from stacking
in the vehicle.
Data could be collected from desired road profile according to customer usage
conditions and simulated on equipment.
1) PACKAGING TEST CENTER- SAMPLE PACKAGING TEST
Compression Test
16
This test method is used for determining the ability of packaging to withstand the damages
occurring during handlings. It also gives the results about the packaging strength and loading
capacities.
Wooden Pallet
Compression Test
Carton Box
Compression Test
1) PACKAGING TEST CENTER- SAMPLE PACKAGING TEST
Enviromental Conditional Simulation Test
17
This test method is used for determining the ability of packaging to withstand under specific
enviromental condition such as extreme temperature, humidity, sun effect etc.
Wooden Pallet
Enviromental
Conditioning
Carton Box
Enviromental
Conditioning
1) PACKAGING TEST CENTER- SAMPLE PACKAGING TEST
Drop Test
18
This test method is used for determining the ability of packaging to withstand impacts caused by
dropping or throwing.
1) PACKAGING TEST CENTER
19
Advantages of Packaging Testing
Validation processes of features identified by specifications, global regulations and contracts
Design validation and design development processes in packaging development
Data input for meeting Safety and Quality standards
Addressing the issues occur during transportation
Identify cost reduction oppurtunities for packaging products
20
Daily 950 shipping unit controlled with Smart Weighing System
21 2) SMART WEIGHING SYSTEM 21
Smart Weighing System implemented at Ford Otosan Part Export Distribution Center where we consolidate
parts from 132 different Turkish suppliers and ship them to Ford North America, Ford Sollers Russia , Ford
South America, JMC China.
Safety of Life at Sea (SOLAS)
Secure Supply Chain & C--TPAT (Customs-Trade Partnership
Against Terrorism)
Prevent quantity claims (missing, wrong or more part shipments)
Customer Satisfaction
Where in Use?
Purpose of the Project
2) SMART WEIGHING SYSTEM
22 22
Weight Barcode
Label
OK NOK
• Part packaging info
• Part weight info
• Packaging weight info Label Reading Process with RF
System
• Part no (Master Label)
• Customer code (Master Label)
• Quantity (Master Label)
• Weight Barcode Label
OPTIMIZATION QUARANTINE
23
FORD OTOSAN’S
DIGITAL VISION
DIGITAL VISION LINKED TO FORD OTOSAN STRATEGIES
Be the most preferred brand across a
full line of products by meeting the
needs and expectations of customers
Be the number one automotive brand in
customer satisfaction for sales and
after-sales products
Provide innovative products and
services by keeping creativity at a
high level across the business
Be the most preferred company by aiming at for
perfection in human resources processes and
so deliver an ideal working environment for all
people
Grow organically and inorganically by
developing new products and new
markets
Brand
Customer
Growth
Innovation
People
Ford Otosan Strategic Vision
DIGITAL VISION FOR 2020+
Brand
Customer
Growth
Innovation
People
Ford Otosan gets awarded additional manufacturing contracts from Ford
due to the high manufacturing efficiency driven by data-based efficiency
and quality programs and automation
Ford Otosan has established a “Digital workspace” with employees working
in innovative offices, remotely from home or mobile, supported by digital tools
Connected
Employee and
Organization
Connected
Supply Chain There is automated real-time end-2-end data flow along the supply chain
Connected
Manufacturing
Ford Otosan captures new development contracts from Ford and externals
because of high efficient in its PD organization
Connected Vehicle Ford Otosan is running the largest fleet of connected trucks in Turkey with
profitable fast growing business providing services to truck owners and
ecosystem partners
Ford Otosan uses big data analytics
to understand customer needs and
offer customized products
Dealerships are fully digitized
with digital sales tools and direct
link to the Otosan CRM
Connected
Customer/Dealer
Forecasting
is based on big data analytics
All data and knowledge is
centrally available and leveraged
with analytics capabilities
Ford Otosan Digital Vision
CONNECTED SUPPLY CHAIN
CONNECTED SUPPLY CHAIN
1A ) SUPPLIER STOCK AND PRODUCTION PLAN TRANSPARENCY 28
CMMS
Stock PVS
Ford Otosan
Supplier
Supplier
Carrier
Supplier
Stock
Intransit
Stock
Real Time Planning and
Shipment Traceability Carrier
Extend the digitalization to suppliers
Decrease the production loss based
on the supplier
Real time planning & shipment, backlog
and critical parts tracking.
Increase the flexibilty : Reaction time
descrease
Operational time saving (SCM, Logistic,
PP team)
Integration with Vehicle Tracking System
Goal; to build a cloud platform to integrate
the systems of both suppliers’ and Ford
Otosan’s stock level and production plan.
CONNECTED SUPPLY CHAıN
1B) INBOUND LOGISTICS VEHICLE TRACKING AND MANAGEMENT 30
Vehicle Tracking System
GPS Position
Info GPS Time Info
ASN Content
Loading Plan
Time Window
Maps
Control/ Check Points
Systematical follow up
Rapid and insant information
Traceability
Early warning
Secure Supply Chain
CONNECTED SUPPLY CHAıN
1C&D) REAL TIME STOCK MANAGEMENT & TRACKING OF CONTAINERS 32
Racks with RFID Tag Forks with RFID Antenna
CONNECTED SUPPLY CHAıN
1E) JIS DELIVERY 34
Current Material Flow (non sequenced)
34
Ford Otosan Assembly Line
• Short term program
fluctuations
• Higher inventory level at
plant and suppliers
• Inefficient stock areas
Ford Otosan
Supplier Network
Sequencing Material Flow
• 3 days production sequence fixed
• Lower inventory level at plants
• More efficient storage areas
Ford Otosan Assembly Line
• 3 days production
sequence fixed
• Lower inventory level at
plants
• More efficient stock areas X
Thank You...
“The one who manages Logistics better will be one step
ahead of the other.”