5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
-
Upload
srikanthsree -
Category
Documents
-
view
214 -
download
0
Transcript of 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
1/15
Your logo
Warehouse Management at Ford withS P EWM
Maryan Jacek - Ford Motor Company
Philippe Bouchot - Deloitte
SAPience.be User Day 2012
1
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
2/15
Your logoAgenda
Introducing Ford Motor Company & Deloitte
Why SAP Extended Warehouse Management
Scope & Implementation Approach
Challenges
Lessons Learned
Business Benefits using SAP Extended Warehouse Management
Next Step for EWM at Ford
Q&A
SAPience.be User Day 2012 2
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
3/15
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
4/15
Your logoIntroducing Ford
SAPience.be User Day 2012 4
Dealers /RetailersSuppliers
Packagers
Warehouses Consumers
Purchasing &
SCM
Warehouse
Operations
Inbound
Transportation
Outbound
Transportation
Service Parts
Release
PS&L - 5 Key
Functions
Key Figures
2.840 suppliers
2.808 ship-to addresses
227.000 parts
21+ European markets
86 other countries
8 parts depots in Europe
130.000 order lines/day
240 outbound truck /day
62.500 inbound trucks / year65.000 outbound trucks / year
UKDaventry
166.000 m
115.000 parts
Germany Cologne
120.000 m
135.000 parts
Spain Valencia
39.000 m
83.000 parts
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
5/15
Your logoWhy SAP Extended Warehouse Management
SAPience.be User Day 2012 5
Alliance to develop a ServiceParts Management Solution
Intellectual Property
Know-how
Capability
Scalability
SAP ERPEnterprise Resources Planning
SAP CRMCustomer Relationship Management
SAP SCMSupply Chain Management
SAP SPPService
Parts
Planning
SAP EWMExtended
Warehouse
Management
SAP SPM SolutionNovember 2001
Ford Motor Company &
Caterpillar starts a
contractual alliance aiming
to build a new Service parts
Management solution
January 2003
Deloitte joins the
program as system
integrator
July 2002
SAP is selected to co-
develop the solution
SAP EWM
SAP Extended Warehouse Management as part of the new SPM Solution to cover specific warehousing business requirements
High Volumes
Complex Multi-Step Processes
Specific functionalities (Slotting, Rearrangement, )
EWM becoming the cross-industry standard Warehouse Management Solution from SAP
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
6/15
Your logoFord Warehouse in France
SAPience.be User Day 2012 6
Key Figures
36.000 m2
32.000 materials
Carousel (40% of the warehouse materials)
Inbound: 800 Lines (10 Trucks)
Outbound: 15.000 Lines (20 Trucks)
150 workers, 1 shift
320 dealers served
ISO 14001
Systems to be replaced by SAP EWM
PORTS: receiving and putaway
S&R: reserve stock and replenishment
SCRAP: scrapping
CYCLE COUNT: counting
MOSAIC: lost and found
GOLIAT: picking, packing and shipping operations
Introduction of Radio Frequency
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
7/15
Your logoFunctional Scope
SAPience.be User Day 2012 7
Inbound Processing Storage and Operations Outbound Processing
CoreW
arehouseOperationsand
InventoryManagement
Receive ASN data
ASN Validation & Correction
Transporation Unit Arrival
Manage Transportation Unit
Goods Receipt
Putaway Bin determination
Unload Transportation Unit
Internal Routing
Slotting
Deconsolidation
Putaway
Returns / Reverse Logistics
Rearrangement Order deployment
Inventory Counts
Replenishment
Freight Order Management
Route Determination
Wave Management
Picking Bin Determination
Warehouse Order Creation
Work Assignment
Picking
Packing
Staging
Loading & Goods Issue
Kit-to order
Transportation Cross Docking
Picking GR/ Push Deployment
Yard Management
Packaging Specification
GTS Integration
EH&S Integration
Integration to QIE
RF support for all exec.processes
Batch Management
Material Flow System
Serial Numbers
Cross
Processes
Supporting
Functions
Goods Receipt - Optimization
Kit-to stock
Manual outbound deliveries
RFID Enablement
Warehouse Cockpit
eSOA enablement
Catch Weight
Labour Management
Production Supply
Opportunistic Cross Docking
Merchandise Distr. X-Docking
Task Interleaving
Execution Constraint
Semi-System-Guided work
Graphical Warehouse Layout
Integration to Transp. Processes Claims & Returns
SAP SCM-EWM 5.0
SAP SCM-EWM 5.1
SAP SCM-EWM 7.0
SAP SCM-EWM 7.0 EP1
Ford France
EWM Scope
Ford Europe
EWM Scope
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
8/15
Your logoImplementation Approach
SAPience.be User Day 2012 8
Global Template ApproachGlobal blueprint
Global prototyping80 % commonality
Documen-tation
Structures
and settings
Globalcustomer
developments
Organiza-
tional structure
Master datadocuments
Country
versions
Localdevelop-
ments
Global and inte-
grated processes
Localprocesses
Global
Template Regional/Local
Requirements
Documen-tation
Structures
and settings
Globalcustomer
developments
Organiza-
tional structure
Master datadocuments
Country
versions
Localdevelop-
ments
Global and inte-
grated processes
Localprocesses
Global
Template Regional/Local
Requirements
Ford France Implementation Strategy
Inbound Go-Live (big bang)
Unloading, Quality Management, Putaway to primary bins
Outbound Go-Live by Zone split in 3 phases
Outbound & Internal processes (Waving, Picking, Shipping, Physical Inventory,
Replenishment, )
Approach by phase/zone
Define processes, areas and volumes to reduce risks and impact on the operations
Learn from each phase
Phase Area % Shipping Lines % Materials Stored
Inbound
Outbound 1 Carrousel 28 % 41 %
Outbound 2
Pilferable
2 % 2 %
Large Parts
Engines
Pack. Mat
Outbound 3Whse B 11 % 10 %
Whse A 59 % 47 %
Warehouse Structure
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
9/15
Your logoChallenges
SAPience.be User Day 2012 9
First Ford warehouse worldwide
Business
Process harmonisation from Global Template
Introduction of RF scanners
Change Management
Ship Orders from two different systems (Implementation Strategy)
People
IT
Performance
Upgrade to 5.1
Interface to automated warehouse system (Carousel)
Temporary Interfaces (Implementation Strategy)
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
10/15
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
11/15
Your logoLessons Learned
SAPience.be User Day 2012 11
Involve key users in the project team as soon as possible Practical training
Go for phased go-live approach limits impact & risks
Privilege SAP EWM standard in process designDo not hesitate to
challenge existing processes
Transportation PlanningFord Specific Development
Transportation Planning driving the outbound process
Daily deliveries assignment to trucks
Done by external Transportation Planner
Option 1
Keep existing process
Develop Ford specific
Transportation Planning
Option 2
Fix Transportation Planning
SAP Standard RouteDetermination
IT Benefits
SAP Support
Reduce Development efforts
Reduce Testing efforts
Business Benefits
Controlled flexibility
Reduced change on operations
Educate People
Prefered Option 10 months after Go Live
Change to SAP Standard
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
12/15
Your logoBusiness benefits using SAP Extended
Warehouse Management
SAPience.be User Day 2012 12
On the shopfloor
Improve Tracking & Monitoring
Real time information at any stage of the process via the Monitor
Detailed shipping box information
Improved communication with customers
Increase Quality with RF confirmation all processes
Picking
Same picking performance although RF scanning has been introduced
Reduced picking waiting time with new Replenishment process Same picking denial rate although Inventory has been reduced by 20 %
Improved picking error rate (0,16 0,12)
Inventory Management (integration with SAP Service Parts Planning)
Reduced Inventory by 20 %
Reduced Obsolescence and Scrapping by 10 % (Ford of Europe)
Increased Fill rate (+ 0,5 97%)
Continuous Improvment using SAP Extended Warehouse Management
Information availability & accessibility for analysis
Flexibility in standard processes - Wide range of parameters & settings (Customizing and Application)
Improvments implementation done internally (New Transportation Planning & Waving in 2010)
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
13/15
Your logoNext Step for EWM at Ford
SAPience.be User Day 2012 13
EWM Implementation in Daventry UK - Ongoing
Live Inbound
Live Outbound for 50 % of the shipping volume
Final Outbound Go Live in July
Upgrade to EWM 7.0 EP2
Implementation in Germany & Spain
Voice Picking in France
GlobalTemplate
Central European Planning
Whse FR
Whse UK
Whse GE
Whse SP
Other Whse
Com FR
Com UK
Com GE
Com SP
Other Com
Ford BTR Europe Rollout Plan
Planning
Warehousing
Commercial
SAP ERPEnterprise Resources Planning
SAP CRMCustomer Relationship Management
SAP SCMSupply Chain Management
SAP SPPService
Parts
Planning
SAP EWMExtended
Warehouse
Management
SAP SPM Solution
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
14/15
Your logoQ&A
SAPience.be User Day 2012 14
Questions ?
-
8/13/2019 5 4 SAPiensdfsdfce Be UserDay2012 Ford Deloitte
15/15
Thank you!
Your logo
SAPience.be User Day 2012 15