WAREHOUSING&MATERIAL FLOW SÁRVÁR SITE
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1 WAREHOUSING&MATERIAL FLOW SÁRVÁR SITE
2 About Flextronics 2
3 Flextronics West Hungary Industrial Park (IP) Slovakia Ukraine Austria Sárvár Althofen Zalaegerszeg Tab Slovenia Croatia Serbia Romania 3
4 Manufacturing units Sarvar site Automotive High Reliability Solutions Assembly Warehousing Spare parts service Testing Ultrasonic and vibration velding Lenovo High Velocity Solutions Computing Assembly Warehousing VMI service Customization BTO, CTO Nespresso Industrial&Emerging Industries Assembly Warehousing Spare parts service Distribution Plastics Industrial&Emerging Industries Moluding&Painting Assembly&Preassembly Warehousing Printing Incidental text: Arial 9pt. 4
5 Our Costumers: 5
6 Sárvár Campus Bird s-eye view Austrian Auto Flex Automotive Assembly and Lenovo Computing Assembly LENOVO Warehouse Shipping wh Hirsch (EPS-cushions) SCA (Carton box) Flex NESPRESSO Flex Automotive Robot paint lines PLASTICS Automotive PLASTICS Nespresso Flex Automotive Plastics moulding Tampo printing Incidental text: Arial 9pt. 6 6
7 Sárvár Campus Stores NES EXTERNAL Flex Automotive LENOVO Warehouse Shipping NESPRESSO Plastics Incidental text: Arial 9pt. 7 7
8 About Store Parameters: Warehouse: Nespresso Plastics Automotive Shipping TOTAL: Warehousing type: Receiving: Production replenish type: Kitting&Supermarket Chaotic warehousing, Multi item locations, RF scanners One piece flow, box by box handling, Bookkeeping, labelling with Skid (Unique ID) Directly from to Moulding production Automatized preparation, Supermarket Directly from to Painting WIP& Supermarket (Porsche) Materials Number Of Items Volumen (Monthly AVG) Number of Items Volumen (Monthly AVG) Number of Items Volumen (Monthly AVG) Number of Items Volumen (Monthly AVG) Number of Items Volumen (Monthly AVG) Receiving: Movement's to WIP: F.G handling: Packaging handling TOTAL: Total Size: 3603m m m m m 2 Store size: 2834m m m m m 2 Standard locations: 1778pallets 1979pallets 1650pallets 1240pallets 6647pallets Supermarket size: 363m 2 0m 2 280m 2 20m 2 663m 2 Supermarket loc.: 215loc 0loc 1304loc 42loc 1561locations Number of prod. Lines 6 Lines 95Machines 190 Lines 25Line 316Lines/Machines Production type: Production lines 95 Moulding machines Cell production Cells &Robots 8
9 Value Stream Mapping NESPRESSO Kitting Level Flow Start Sequence 1. Detection of production orders 2. Priorityzation 3. UPL List Printing Inventory Check of Materials 5. Ordering Materials in BaaN Prod 6. Order Consolidation 7. Atlas receipts the order 7.2. Receipt of Materials on N51from N50 Narration Trolley Work Station Station with computer End 8. Material Takeover 9. Dock to Locations Sorting 10. Kitting process 11. Kit ready 11. UPL booking sec check and takeover to prod. 9
10 Kitting Benefits - Nespresso Minimized WIP value / Exact quantity of prod orders material Full control of high value parts Real time booking (UPL) and delivery Increase WIP stock accuracy Control stock discrepancy in WIPL02 Start line scheduling application on kitting Quality improvements on the kitting(chassies) On line booking to production Daily cycle count for high $ parts 10
11 Production Lines Replenishment Process - Automotive Start 11
12 Automotive - Packaging Movements 12
13 Material flow - Plastic R e l a t e d s i t e s Automotive Shipping Nespresso Plastic Moulding Raw Material for Moulding Plastics Semi-finished materials to AUT, PAINT Plastics Semi-finished materials to NES Automotive painted parts Plastics finished goods Automotive finished goods (BASSBOX) Empty returnable packaging from NES, AUT, Moulding Empty returnable packaging from PAINT High volume parts Low volume parts 13
14 Material flow - Nespresso R e l a t e d s i t e s Lenovo Nesp presso Ship pping Shipping Nespresso Plastic Moulding Empty returnable plastics packaging Raw materials Nespresso finished goods Plastics finished goods Nespresso spare parts (fg) Plastics semi-finished materials to NES Nespresso painted parts High volume parts Low volume parts 14
15 Material flow - Automotive R e l a t e d s i t e s Automo otive Suppliers (out of campus) Shipping Nespresso Plastic Moulding Purchased Materials ~8-8,5k Box (5-600 pal) / mth Plastics Semi-finished materials ~30-33k Box (2-2,2k pal) / mth Automotive painted parts ~3,5-4k Box (250 pal) / mth Empty returnable packaging ~30-33k Box (2-2,2k pal) / mth Automotive finished goods ~25-30k Box (1,8k pal) / mth High volume parts Low volume parts 15
16 Material flow - Shipping R e l a t e d s i t e s Automotive Nespresso Automotive finished goods Plastics Semi-finished materials Empty returnable packaging Nespresso finished goods Shipping Plastic Moulding Plastics finished goods Nespresso spare parts (fg) Automotive painted parts Nespresso painted parts High volume parts Low volume parts 16
17 Packaging materials - layout M o u l d i n g Nespresso Tool shop M o u l d i n g Automotive building Paint building 17
18 Packaging materials - matflow PLS PLS NES Full Empty package from moulding warehouse NES, AUT, PAINT to moulding warehouse NES, AUT, PAINT Recycled package from Tab AUT PAINT 18
19 Thank you 19
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