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Apresentação michael toth


Apresentação do Palestrante Michael Toth - Wokshop Logística (16 de Maio, Balneário Camboriú)

Apresentação do Palestrante Michael Toth - Wokshop Logística (16 de Maio, Balneário Camboriú)

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  • 1. SENAI International Workshop – LogisticImpact of Material Flow Changes on theSustainability of Global Supply ChainsDr.-Ing. Michael TothFraunhofer IML
  • 2. The Fraunhofer-Society Locations in Germany■ 60 Institutes■ 18,000 employees■ 1.8 billion Euro research volume ■ 2/3 of this volume are generated with orders from industry and with publically financed research projects. ■ 1/3 of it is contributed as basic funding by the federal and Länder governments  Institutes and facilities  Further locations© Fraunhofer IML
  • 4. The Fraunhofer IML Data and Facts■ Founded in 1981■ More than 205 scientists, 200 student assistants■ 800 projects in a year■ Turnover of 22 million €■ Thereof 50% from industry, trade and services■ Branches and project centers in Frankfurt on Main, Prien on Chiemsee, Hamburg■ Cooperation with HSG St. Gallen (Switzerland), Georgia Tech (USA), Lisbon (Portugal), Shanghai (China), Rio de Janeiro (Brazil)© Fraunhofer IML
  • 6. Lab: openID-Center■ 1500m² laboratory for industry and research■ Showcase for all state-of- the-art-technologies in the supply chain■ Integrated hard- and software from partners and sponsors© Fraunhofer IML
  • 7. Lab: Packaging Centre ■ Simulation of static, dynamic and climatic loads / forces on packaging systems ■ 400 m² of testing area and 6 employees ■ 60 to 80 projects per year ■ High tech testing equipment ■ 4 climatic chambers ■ 2 vertical vibration tables ■ 1 tension / compression test machine ■ 1 horizontal impact test system ■ 1 precision drop hook and table ■ 1 vertical shock test machine© Fraunhofer IML
  • 8. Logistics can no longer be Managed by the way ■ The days of being able to control logistics by intuition are over. ■ Logistics has become an interdisciplinary, highly complex discipline. ■ More than ever, logistics are called upon to contribute to issues of the future. ■ It is important to recognize logistics as technology and as a response to many social issues.© Fraunhofer IML
  • 9. Creating tomorrow’s individuality with 75% of today’s resources.Individuality Efficiency
  • 10. Key Issues for the Logistics of the Future Environment and Transportation Sustainability Management Urban Supply Logistics-as-a-Service Real-Time Flexible Design Competence Logistics Systems© Fraunhofer IML
  • 11. Sustainability in Logistics Networks Social Economic Ecological Working Fair trade Ressource conditions efficiency Greenhouse gas emissions Education and Renewable qualification energy Noise emissions Land use Waste reduction© Fraunhofer IML
  • 12. Focusing Only on Production Technology is InsufficientHigh-value consumer andinvestment products arecreated in manufacturingnetworks. 2nd tier 1st tier OEM Transport Production 1 Transport Production 2 Transport Production n Distribution Value Value Value - Provide Pick Store Pick Provide creation creation creation Store Pack 1.1 1.2 1.nFields of action in holistic Production boundaries:consideration of processes Production technology Efficient usage offrom the supplier to the and processes logistics resourcesconsumer© Fraunhofer IML
  • 13. Logistics Designs, Plans, and Executes the Production Environment… Production organization Supply concept Production network Factory building and layout Informationsfluss WA EM Halle EM 5 person LDL LDL Kunde EM Halle Halle 4 EM BSF 6 VM/BSF Zulieferer Produzent Handel Entsorger ProductLife - -Chain Halle 3/ A VM VM VM M aterialfluss WEGT WEKT EM Production and I&C Halle 2 Halle 1 logistics facilities Logistics processes Process Modelling Desktop Desktop Web Web Mobile Mobile Halle 7 Client Client Client Client Client Client Business Event WA Lagern EXP CARNOT EXP CARNOT Business Logic 11 Business Logic Business Logic 22 Business Logic Kommiss- Deployment Process Engine Process Engine (EJB) (EJB) (EJB) (EJB) Model Repository ionieren JDBC JMS JCA JCA SOAP JEE Application Server Messaging Messaging ERP ERP Web Service Web Service (e.g. Host) (e.g. Host) (e.g. SAP) (e.g. SAP) (e.g. PI, OMNI) (e.g. PI, OMNI) Verpacken Audit Trail Database ...and determines its sustainability.© Fraunhofer IML
  • 14. Examples of the General Potential in Logistics NetworksGlobal Supply Chain Local Supply Chain■ Increase capacity usage through ■ New Supply Processes bundling of transports ■ Reduction of noise and gas emissions ■ Improved ratio of emissions over ■ Resource Efficiency applying Lean transport performance Concepts ■ Higher stock level required to absorb Perfor- peaks mance ■ Less flexibility Position through Scope of decisions ow n decision■ Less express transports, e.g. air cargo Sustain- ■ Short lead times, low stock levels, but Costs ability high resource demand ■ Future Material Flow – Multishuttle© Fraunhofer IML
  • 15. Dynamics in Global Supply Chain Operations Supply chain Processes and resources Supply chain Markets performance  Process quality events and risks  Demand dynamics  Material quality  Process stability  Growth, Competition  Supplier performance  Resource availability  Forecast errors  Transports disruptions  Sales promotions Dealer / Dealer / 1st tier 1st tier LSP LSP OEM OEM LSP LSP Customer Customer Wrong delivery Capacity Natural disasters shortage Machine Transport delays Delayed vessels Rework breakdownMaterial defects or air freight Customers IT-breakdown  Order changes Terrorism  Adhoc orders Supply shortage Strike  Delivery date Quarantined Machine Staff modifications Accident customs goods maintenance unavailability s Traffic © Fraunhofer IML
  • 16. E²Log Project – Sustainability Through Energy Efficiency■ E²Log – Energy Efficiency in Logistics and Production■ Analysis of effects of decision in production on the energy efficiency of the entire supply chain■ Integration of the objectives costs, performance, and energy■ Development of methods and instruments for: Long-term Short-/ medium-term Strategic Design© Fraunhofer IML
  • 17. Food Chain Management Today < ■ Waste of food ■ More traffic • About 50% of vegetables and fruits in • Higher delivery frequency UK supermarkets have to be • Therefore more empty trucks disposed • Just in UK: 17 million tons per year • Disposal cost: about 20 billion Euro in UK Neither sustainable nor efficient nor effective© Fraunhofer IML
  • 18. Sustainable Food Chain Management Packing Rapid Testing Sensor Technology AutoID Logistic Warehousing Custmoer Service© Fraunhofer IML
  • 19. Carbon Footprint: Volkswagen Amarok Production SME Bremerhaven Harbour/ Harbour/ Wedemark Airport Airport Salzgitter Production Cross Dock Bremerhaven CKD-AnchietaSupplier Santos Pacheco Buenos Aires Santos Buenos Aires Hannover, Germany Pacheco, Argentina © Fraunhofer IML
  • 20. Carbon Footprint: Volkswagen Amarok Production ■ Long and complex supply chain ■ Parts variety: approx. 650 different parts ■ Supplier variety: almost 400 European suppliers ■ Different keeping quality: depends on the material, parts (e.g. tires) ■ Obsolete materials: ramp-up and -down of parts ■ Limited supplier capacity, high market demand: no flexibility for significant deviation from forecast ■ … SME Harbour/ Harbour/ Airport Airport Production Cross DockSupplier © Fraunhofer IML
  • 21. Global Supply Networks with many Locations cause Intransparency … Capacity Transport Localization (GPS) Production Progress UtilizationGoods Receipt Inventories Goods Issue Execution Systems PPS ERP BDE© Fraunhofer IML
  • 22. Real-Time Logistics: Fast Identification and Transparency■ Challenges: ■ information must be available on time in full ■ find standards for cross-company implementation of Real-Time Auto-ID-Technologies (e.g. RFID) ■ enable intelligent information sharing, execution and event handling© Fraunhofer IML
  • 23. A new Software Approach to Evaluate Global Ecological Sustainability Supply Chain Monitoring Demand Supply Capacity Chain Planning Simulation Transport PlanningeLog@istics Award 2011 combining ECOnomic & ECOlogic objectives in Logistic Assistance Systems © Fraunhofer IML
  • 24. ECO2LAS: Carbon Footprint for the Supply Chain© Fraunhofer IML
  • 25. Sustainable Resource Efficiency: BETA Project at FIAT Betim, Brazil ■ Initial Situation: ■ FIASA (Fiat Automoveis SA): 3.150 cars/da (14 models) ■ FPT (Fiat Powertrain): 3.300 engines + 3.500 transmissions ■ LSPs for all in-plant-logistics for over 15 years ■ BETA Project (started in 02/2012): ■ Insourcing of all logistics activities in FIASA Security and FPT ■ Goals: World ■ Better quality of logistics processes Equip- Lean ment Class Logistics ■ Improve security Logistics ■ Reduce Logistics Costs IT/WMS© Fraunhofer IML
  • 26. Sustainable Resource Efficiency: BETA Project at FIAT Betim, Brazil ■ Structuring and mapping of Logistics processes ■ Transparency on current logistics processes ■ Identification of cirtical procedures ■ International Bench Marking (Best Practices) ■ Define short-, medium- and long-term Receiving Storage Line improvements Feeding Truck entry ■ Develoment and mapping of ToBe- Load Check Goods receipt Proecesses Empties load Label print ■ Document new standard processes Truck exit Buffer ■ Roll out of best practices in all shops Line ■ Keep knowledge of processes Storage demand Material Picking Delivery ■ Facilitate continuous improvement© Fraunhofer IML
  • 27. Sustainable Noise Emissions: Urbanization meets FactoryCurrent Plant and Supplier Concept■Minimize stock levels and coherent lot sizes through in time supply■Just-in-time supply of components with reduced delivery quantity and higherfrequency© Fraunhofer IML
  • 28. Sustainable Noise Emissions: Evaluation of Future Scenarios ■ Analyze of different distance clusters and supply concepts to find solutions which reduce noise and gas emissions and guarantee reliable cost efficient supply. Standard Supply Palets, Boxes (GLT) Small Boxes (KLT) Special Supply Seats Tires Engines Vehicles Fully Build Up Units (FBU) OEM Ext. Warehouse and Cross Dock DC Direct nesxt to plant Distance Cluster 1 (DC 1) DC 2 3© Fraunhofer IML
  • 29. Sustainable Noise Emissions: a new Paradigm Distance Cluster 3 ■ Simulation basedSupplier Locations study of different future Distance Cluster 2 scenarios (demand, structure, processes). Distance Cluster 1 Highway ■ Evaluation of Border transports, gas and noise emissions and identification of sustainable supplyUrbanized Area Ext. Warehouses (e. g. Cross Docks, strategies. ■ Identification of a Road- OEM Map for future supply chain management. Distribution Route © Fraunhofer IML
  • 30. Multishuttle Move – a new Material Flow Paradigm inside the Factory Diese Entwicklung wurde gefördert durch:© Fraunhofer IML
  • 31. Diversity of Logistics – Sustainability is a mayor Issue!© Fraunhofer IML
  • 32. Logistics: connecting ... ... and communicating! Dr.-Ing. Michael Toth Muito obrigado pela atenção! phone: +49 231 9743 169 fax: +49 231 9743 234 email: Fraunhofer IML© Fraunhofer IML