The automotive industry is no stranger to technology. It’s also no stranger to the rapid pace of change that’s overtaken global manufacturing in the early 21st-century. And when it comes to planning and organizing your entire automotive supply chain, advanced planning and scheduling (APS) is the key that will unlock increased ROI and decreased lag times. APS represents a sea change from traditional methods that looked at materials and production capacity as separate things, a view that often led to incompatible plans. Adoption rates of APS in the automotive sector are on the rise, paralleling the rise of make-to-order and additive manufacturing; and the increasing complexity of the automotive manufacturing world as a whole. And it’s that last factor that we’re going to focus on today, the increasing complexity of the automotive world and how APS can help. Whether by assisting with inventory leveling or by helping planners better schedule materials deliveries, APS can be a boon at every stage of the automotive manufacturing supply chain.
Let's say you’re a bartender in a sleepy neighborhood pub in your city. Your place might reasonably be called a dive bar, and you have a handful of regulars who come and order basically the same drinks week after week. As a result, your ordering process for restocking the bar is extremely simple. With little variation, you expect to go through predictable quantities of gin, tonic, bourbon, and cheap beer every month, and you’ve simply placed a standing order with the local distribution company to restock these things in the same quantity every so often. Life is pretty easy.
All the way at the far end of the supply chain, when an automobile reaches its end consumer, it looks like they’re buying one large item. But automotive manufacturers know differently—they know that each car on the road is really comprised of about 20,000 different parts, and all of them had to come from somewhere. After being sourced, they had to be stored, allocated for various production plans, brought to the production plant, and assembled into a road-worthy vehicle that someone could drive off the lot at their local car dealership.
Picture a scenario in the near future: you’re driving down a long stretch of highway between your home and a vacation destination a few hours away, when all of a sudden your car gives you an alert suggesting that you pull over and wait for assistance. You’re confused, and maybe a little annoyed, but you know that if your car’s sensors are going off there’s probably a real issue at hand. Luckily, your car didn’t just alert you that something was amiss—it also alerted a nearby garage, giving a detailed account of which parts the issue affected. Thus, within five minutes a repairman pulls up beside your car.
Topics: Automotive Industry
In the past few years, sustainability has become a topic of considerable importance throughout the automotive industry. As the automotive supply chain becomes increasingly globalized, businesses are now more than ever faced with the Herculean task of managing not just the logistics and costs associated with a complex web of global suppliers, but with the environmental impact and long term sustainability of the associated businesses practices. While this process is often daunting, it has grown in importance to the point where manufacturers ignore it at their own peril. Even beyond supply chain considerations, many businesses are finding that discussions of sustainability bring up questions and dilemmas that they’ve never faced before, from deciding on acceptable trade offs between sustainability and profitability and uncovering areas where sustainability increases profitability, to developing new KPIs for managing vendors and suppliers.
Topics: Automotive Industry
It’s still about a month until Thanksgiving, but you may already be deep into the planning process for the big event. Some of your friends and family are flakey, so you won’t have a full list of RSVPs until much closer to the holiday itself, meaning that when you sit down to sketch out what dishes you’ll be cooking and what ingredients they’ll require, you’ll have to use a combination of confirmed and projected attendees. For some dishes, it might be easier to wait until a few days before Thanksgiving to get the necessary ingredients, but you’re worried that your nearby grocery stores might run out of a particular brand you like if you wait too long, and there are some items that need to be purchased well in advance because they need to be stale or overripe before they can be used, like bread for stuffing or bread pudding.
Let's say you're an OEM, with a sleek manufacturing space and a sophisticated, technologically cutting edge process for creating a particular automotive part. But you have a problem: At this point, your incredibly sophisticated production techniques aren't not being complemented by an equally sophisticated, multi-level approach to production planning and resource scheduling. This results in a disconnect between the high quality of your products and your ability to maximize capacity and meet customer delivery requirements. How can you build towards a production planning workflow that complements your product and fulfills your business goals?
IT pioneer and philosopher Ted Nelson, who coined the term hypertext, once famously said, "The good news about computers is that they do what you tell them to do. The bad news is that they do what you tell them to do." Historically, in the automotive supply chain, this couldn’t be more true. New technological developments like early computerized workflows and simple process automation were hampered by information silos and integration issues not because the technology lacked sophistication, but because they still had to be told what to do in very specific ways.
Imagine you own and operate a pin factory at the dawn of the Industrial Revolution. One day, you come in and announce to your workers that you’ll be implementing steam powered machinery into your production processes, completely reimagining many existing workflows in the process. How do you think your employees, especially those involved in planning out production workflows, are likely to react? Some of them might be excited or intrigued, certainly, but many others are likely to meet the news with apprehension or even distrust. After all, they were doing just fine making pins by hand all this time.
Here at the flexis blog, we’ve spoken on more than one occasion about the inherent difficulties of job shop scheduling and the significant value added potential of developing a smart, digitized workflow for non-timed production planning. Because there is no known algorithm that can efficiently solve the problem of non-clocked production under all circumstances, the pen and paper production planners of the world are almost certainly failing to optimize their machine and personnel usage in job shop production settings. On the other hand, the path to optimal planning can appear dauntingly complex. To help you as you navigate these hurdles, we’re happy to present a case study on ENisco’s successful attempt to master the job shop problem.