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4. Kit preparation project

4.5 Practical implementation

4.5.1 Planned introduction steps

101 As a further comment to this section it is worthwhile to note that the role of the kit preparation process as designed for the body shop environment is dual. On the one hand we have that of streamlining the daily operations already performed in the AS IS situation by the logistic operators by providing them with the full picking list of the items required for a manufacturing shift at a glance and in an automatic way. On the other hand, though, the kit preparation process and particularly the C3 tool developed to sustain it is targeted at supporting the product family responsibles and floor managers in their search for materials across their whole supply chain: given the peculiarities and time constraints proper of the body shop environment, it has been fundamental to develop a tool not just able of extracting a picking list to perform a simple retrieval of materials, but able to recover the information about those items in order to sustain the operations right from the planning phase up to the actual physical kit preparation.

4.5 Practical implementation

102 Given those points, the following steps for kit preparation process implementation has been defined:

1. Development of the C3 tool to generate the complete list of all the materials needed to perform the manufacturing, starting from the daily plan as prepared by floor managers.

The list of this first step should contain:

a) Complete BOM of all the items required to laminate/bond a part, filtered to include just the materials required in the specific shop. This means that in a clean room environment just those parts needed for lamination must be incorporated in the BOM, while in a body shop environment just those required for bonding, in order to avoid confusion and speed up picking process.

b) Grouping of the items of point a) according to their type. For the two separate cases of clean room and body shop we will have respectively ply kits, tooling, inserts and laminates, tooling, inserts, commercial codes.

c) Association of the BOM with the father’s production order.

d) Association of the previous points a) and b) with the operator assigned for production of any specific item and the related manufacturing phase allocated.

As just introduced, the first implementation step is intended as a rough picking list of all the materials needed for manufacturing on a considered day of production: note that it does not contain the location of the searched items in the related vertical stores, thus still relying on the use of PDAs to retrieve that information from GG2.

Osservazioni Seq.

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Codice Quantità Checklist

610742658 12

610748734 1

610748735 1

Cognome Nome 610801932 1

Ruffatto Matteo 610801933 1

610801934 1

610801935 1

610801936 1

610801949 1

610802034 1

610802035 1

Codice Quantità Checklist

610805542 1

610805545 1

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Codice Quantità Checklist

1 Attività

Laminazione e preparazione sacco

PART_TSL_1.1_FWM/4A/18 - LAMINAZIONE PART_TSL_1.4_FWM/4A/18 - LAMINAZIONE PART_TSL_1.2_FWM/4A/18 - LAMINAZIONE

FWM/4A/18 - LAMINAZIONE - SPAR

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Descrizione FWM / 4A / 18 - LAMINAZIONE

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N S E R T I

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PRESA PRESSURE TAPPING FW - MK3 FWM/1A/18 - BALLAST SUPPORT - BONDED PAD

ID Operatore FWM/1A/18 - BALLAST SUPPORT - BONDED PAD

Turno FWM/4A/18 - LAMINAZIONE - RHC CENTER

FWM/4A/18 - INSERTO FWM / HANGER / VANE

Figure 58- Mockup of the Step 1 software tool developed for CR1 and Body shop

103 2. Full implementation of the dashboard tool to localize all the parts of point 1 in their vertical stores or in their supply chain, when not available in stock. The logic underlying the dashboard page and its information content has been described in the TO BE scenario analysis of this thesis: this second and last implementation step is targeted at the full development and introduction of the IT infrastructure needed to effectively sustain and allow the kit preparation process starting from the MES software C3.

After the starting of the software development phase according to the previous points, a slight modification in the implementation steps has been introduced, in order to speed up the kit preparation process introduction and allow for a more meaningful debug phase to test more advanced features of the newly designed tool from the very beginning of its development.

1.1 Development and introduction of the C3 tool to generate the full list of materials required for manufacturing on a selected day, starting from the daily plan as generated by floor managers. The amount of information present in this updated introduction step is comparable to that described in the previous point 1), though with the fundamental addition of the location of the searched items when they are found to be available in stock.

Moreover, in this point 1.1) a first step towards the traffic light logic implementation of the step 2) has been introduced by highlighting with a red colour material required for manufacturing but not available in a vertical store, as retrieved from GG2.

In contrast to the previous point 1), though, this new implementation step will not feature the ply kit associated to a part to be manufactured in clean room 1, the association of the operator with the assigned manufacturing phase, nor the grouping of items according to their type as described in the point b) for both clean room and body

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Codice Quantità Magazzino Ubicazione Checklist

610742658 12 ALI-E 3

610748734 1

610748735 1 ALI-E 2

Cognome Nome 610801932 1 CR1-H 12

Ruffatto Matteo 610801933 1

610801934 1

610801935 1

610801936 1

610801949 1 CR1-H 6

610802034 1 CR1-H 6

610802035 1 CR1-H 6

Codice Quantità Magazzino Ubicazione Checklist

610805542 1

610805545 1 Z - Sottoscala

Clean Room 1 1 - Cassetto 1

610805547 1 Z - Sottoscala

Clean Room 1 1 - Cassetto 1

610805550 1

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Codice Quantità Freezer Ubicazione Checklist

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Codice disegno Attività

Laminazione e preparazione sacco Osservazioni

Status Status

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Descrizione

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PART_TSL_1.2_FWM/4A/18 - LAMINAZIONE

CR1 VASC F

P E L L I

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PART_MFP_1.2_FWM/4A/18 - LAMINAZIONE

PART_TSL_1.3_FWM/4A/18 - LAMINAZIONE PART_TSL_1.1_FWM/4A/18 - LAMINAZIONE PART_TSL_1.4_FWM/4A/18 - LAMINAZIONE

Turno FWM/4A/18 - LAMINAZIONE - RHC CENTER

I N S E R T I

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Mattina

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FWM/4A/18 - LAMINAZIONE - SPAR FWM/4A/18 - INSERTO FWM / HANGER / VANE

PRESA PRESSURE TAPPING FW - MK3 FWM/1A/18 - BALLAST SUPPORT - BONDED PAD ID Operatore FWM/1A/18 - BALLAST SUPPORT - BONDED PAD FWM/4A/18 - LAMINAZIONE - RHC RWD OB FWM/4A/18 - LAMINAZIONE - RHC RWD OB

Figure 59- Mockup of the Step 2 software tool developed for CR1 and Body shop

104 shop cases. Additionally, following from the need to use built-in features of the WMS software GG2 for searching the availability in stock of the required items, the graphical representation has been changed and simplified as compared with the previous point 1). All those changes did not affect usability of the tool and the scope of the project as regards the initial implementation step 1), while at the same time speeding up the software development phase.

Step 2), instead, remains unchanged compared with the previous planned implementation step, so that overall the software tool developed will converge with the initially designed one.