Professional Documents
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at
7000
6000
5000
4000
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1000
0
GM Ford Toyota VW Daimler PSA Honda Nissan Renault Fiat
Chrysler
Company
50000
40000
30000
Volume
20000
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0
2000 2001 2002 2003
0
Dec- Jan- Feb- Mar- A p r - May- Jun- Jul- Aug- Sep- Oct- Nov- Dec- Jan- Feb- Mar- A p r - May- Jun- Jul- Aug- Sep- Oct- Nov- Dec-
99 00 00 00 00 00 00 00 00 00 00 00 00 01 01 01 01 01 01 01 01 01 01 01 01
68.00%
64.00%
62.00%
60.00%
TPS
58.00%
133W133W 140N 797T 209T 430T 351T 143N 40T 350T 231T 076W 325N 316T 040W 390T 415T404T 395T 065W 210T 186N 465N 450T 153T 391T 970T 081N 652T 651T 630T 702T 525T 828T 191N095N 133W971T 609T 108T 051N 701T 541T 860T 540T 250T 085N 908T 890T 477T 870T 185T 780T 277N 781T
60.0% 3.42%05.6% 00.0% 00.0% 05.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 20.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 1.26%00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 08.5% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 00.0% 1.48% 00.0% 00.0% 00.0% 00.0%
M
I PROVEMENTN
IYEL
IDASONAUG0-1
641.0% 641.0%692.0% 697.0% 689.0% 684.0%688.0% 684.0% 682.0%681.0% 68.00%679.9%679.0% 676.5% 672.7% 672.0% 648.0%665.0% 665.0%662.7% 661.0%66.00%658.0% 655.0%654.0% 653.0% 637.0%649.0% 648.0% 648.0% 648.0%647.0% 646.0% 642.0% 642.0%641.6% 641.0% 641.0% 637.0%635.9% 625.0% 631.0%63.00%628.0% 628.0%626.0% 626.0% 625.7% 625.0%625.0% 60.70%62.00%615.0%60.86%597.0%
DATACOLLECTEDDURNIGLN
IEO
-FFOFQUALS
I
MODELS
REFORM
LEVEL
IMPROVEMENT
MAINTENANCE
AS ON DATE
TKM
0 TIME
• Palletised cargo
• Standardized packaging
TKM SUPPLY CHAIN
CBU LOGISTIC
Steel Steel
Maker Center
CUSTOMER
Material Parts W A
Material Parts
Supplier Supplier DEALER
Information Information P T Insp.
Order Order
Information
Parts Feed Back
P Press shop
Information W Weld shop
TMC &
T Paint shop
Overseas
A Assembly shop
Plants -
Insp Inspection
CKD Parts
TKM LOGISTICS OVERVIEW
STM
THAILAND
SINGAPORE
TKM (TRANSHIPMENT) TAP
PHILIPPINES
Bangalore Plant
South Area - 28 Suppliers
Chennai Transit Dock (370 KMS)
18 Suppliers
INDONESIA
TAM
LOCAL SUPPLIERS DISTRIBUTION
SUPPLIER-A
SUPPLIER-A
SUPPLIER-B TKM
SUPPLIER-B TKM
SUPPLIER-C SUPPLIER-C
S1 S1
Sub Route 3
Sub Route 1
1 Cross 3 S2
S2
Dock
S3 S3
S4
S1 2 S4
Sub Route 2
S2
S3
Cross dock operation for Milk run system
Main Route
TKM
122
day trip truck spec cmt
route area supplier Cyc
cmt kg route cmt kg type cmt kg %
CS011 CHEN W 15.744 5535 1-2 CS01 37 8976 HCV 32 9000 115%
CS012 CHEN B 0.131 45
JG CHEN B(JG) 1.500 1770
CS013 CHEN I 19.500 1627
CS021 CHEN BT 9.608 516 1-1 CS02 17.688 1768 LCV 24 4000 74%
CS022 CHEN R 8.079 1251
CC011 CHEN A 52.722 6571 1-1 CS03 52.722 6571 LDV 55 6800 96%
RM CHEN H 0.800 200 - - 0.800 200.0 - - - -
RM CHEN A 0.100 20 - - 0.100 20.0 - - - -
RM CHEN N 0.100 20 - - 0.100 20.0 - - - -
Standardized Truck Timetable
Logistics on fixed time / variable qty basis
ROUTE NO. CS01
TRUCK TYPE HCV
29.Apr 7:30
Cross Dock 9:00
29.Apr
6km 0.15hrs
Sup-A 29.Apr 9:15
29.Apr 10:15 1.00hrs
1km 0.10hrs
Sup-B 29.Apr 10:25
29.Apr 10:55 0.30hrs
28km 0.40hrs
Sup-C 29.Apr 11:35
29.Apr 12:35 1.00hrs
35km 1.30hrs
High Frequency Delivery
F Delhi & West : 1 times a day
F Chennai, South India : 4 times a day
F Bangalore : 4 - 16 times a day
TKM
Supplier A Supplier D
Supplier B Supplier C
LOGISTIC CONTROL IMAGE TRANSYSTEM
Joint venture between
TKM LOGISTIC
TKM PROVIDER Mitsui corp. (Japan)
Volume Calculation &
Receiving Plan
TCI (India)
Long-Route
Cross-Dock TKM
Suppliers
Short-Route
Suppliers TKM
Truck Status Control
F Procedure
Long-Route : Driving-Members call from predefined points
Local-Route : Controlled by Radio-Receiver up to 60km
5
Stock in Days
Inventory of far off supplier with Cross dock operations – Delhi & Pune
JUST IN TIME
KANBAN SYSTEM
KANBAN OPERATION OVERVIEW
TKML SUPPLIER
11
12
CHECK
SHEET
APL 1-2-2
KBN NO. QTY GRN IN PUR
KBN 111 2
222 222
333
1
4 SYS A/C
XXX Y
KBN PAYABLE
222
1 1
1 1
10
10
LINESIDE CHECK
SHEET
1
APL 1-2-2
KBN NO.
2
QTY
111 2
KBN
KBN 222 1
333 4
222
222 XXX Y
KANBAN
KBN POST
111
9 KBN
222
9
8
APL STTI TGK DNKI NTTF
INCOMING KANBAN
3
TIME LOC1LOC2LOC3LOC4
TRUCK1
TRUCK2
TRUCK3
4
CHEC
K
SHEE
T
7
APL
1-2-2
K
EMPTY BOX
5 6
LOCAL PARTS KANBAN SAMPLE
SUPPLIER
INFORMATION :
TG KIRLOSKAR
TKM
KEY CODE :1234567890 PART DETAILS :
T004-A GLOVE COMPARTMENT
QTY/BOX
55581- 0B010- 00
10
PACKING CODE :
PB10123
516 SEQ NO
1
DOCK
01
PARTS READY FOR DESPATCH AT SUPPLIER SIDE
(BANGALORE SUPPLIER CASE OPERATING WITHOUT CROSS DOCK)
LOADING / UNLOADING USING FORK LIFT
6
Stock in Days
4
Kanban System
3 -1~ 16 delivery / day
- Truck status control
2 by wireless – Time - Frequency increase
control with Mix logistics of
TKM Suppliers
1 Safety Stock Avg
6 Hrs (0.3 days)
JUMBIKI SYSTEM
( Sequential Procurement )
JUST IN TIME
Jumbiki System
ASSEMBLY LINE
Information to CCR
Receiving and
Fax to Supplier
Supply to Line
A1 A1 A1 B1 B1 B1 C1 C1 C1 A1 B1
A2 A2 A2 B2 B2 B2 C2 C2 C2
TPS A2 B2
A3 B3
A3 A3 A3 B3 B3 B3 C3 C3 C3
IN-HOUSE
LOGISTICS
JUST IN TIME
INHOUSE LOGISTICS (Chorukyu System)
WELDING SHOP
CONVENTION SYSTEM TKM SYSTEM
Manufacturing
Manufacturing
TPS
A1 A2 A3 A4
A5 A6 A7 A8
A1 A2 A3 A4
A5 A6 A7 A8
INHOUSE LOGISTICS (SMALL LOT SUPPLY)
INHOUSE LOGISTICS – ASSEMBLY SHOP
SEQUENTIAL SUPPLY SYSTEM
INHOUSE LOGISTICS – ASSEMBLY SHOP
SEQUENTIAL SUPPLY SYSTEM
SUPER FLEXIBLE ASSEMBLY LINE
Before After
2
Achieved 99%
returnable packaging
FUTURE DIRECTION
E - Kanban Supplier
operations
SUPPLIER
S1 S2 S3 S4 S5
SERVICE
SERVICE
PROVIDE
PROVIDE S8 S9 S1 S1 S1
R 0 1 2
R CROSS
CROSS
DOCK
DOCK
Download
Kanban
data
TKM in-house
operations
Cross Dock
operations
TKM e Kanban
information to
Suppliers/
P In-house Bar Cross Dock CROSS DOCK
Coded
W
PC
Kanban
Kanban S1 S2 S
3
S4 S5
Z
S S S S S
Room 1 2 3 4 5
S8 S9 S S1 S1
S S S S S 10 1 2
O
8 9 1 1 1
Store Cards 0 1 2
T
Download
N Insert
cards
Kanban data
A
E Store
Parts
Receive Material
1st Step Mixed Logistics
Purpose:
1) Share logistics between TKM & Supplier.
2) Reduce lot, increase delivery frequency and finally
reduce inventory.
3) Reduce transportation cost.
4) Mutual development and benefit between TKM &
supplier.
Example Mixed Logistics Image