Apresentação do Palestrante Michael Toth - Wokshop Logística (16 de Maio, Balneário Camboriú)

1. SENAI International Workshop – Logistic
Impact of Material Flow Changes on the
Sustainability of Global Supply Chains
Dr.-Ing. Michael Toth
Fraunhofer IML

2. The Fraunhofer-Society
Locations in Germany
■ 60 Institutes
■ 18,000 employees
■ 1.8 billion Euro research volume
■ 2/3 of this volume are generated with
orders from industry and with publically
financed research projects.
■ 1/3 of it is contributed as basic funding by
the federal and Länder governments
 Institutes and
facilities
 Further locations
© Fraunhofer IML

3. THE FRAUNHOFER IML

4. The Fraunhofer IML
Data and Facts
■ Founded in 1981
■ More than 205 scientists, 200 student assistants
■ 800 projects in a year
■ Turnover of 22 million €
■ Thereof 50% from industry, trade and services
■ Branches and project centers in Frankfurt on Main, Prien on Chiemsee,
Hamburg
■ Cooperation with HSG St. Gallen (Switzerland), Georgia Tech (USA),
Lisbon (Portugal), Shanghai (China), Rio de Janeiro (Brazil)
© Fraunhofer IML

5. The Fraunhofer IML
Selection of Latest Topics
PLANNING OF INTRALOGISTICS LOGISTICS MALL
MODELLING PLANNING OF LOCATION
WAREHOUSE MANAGEMENT LOGISTICS AS A SERVICE
RFID APPLICATIONS
MARITIME LOGISTICS
SUPPLY CHAIN MANAGEMENT
SOFTWARE FOR AIR FREIGHT
INTRALOGISTICS
DISTRIBUTION LOGISTICS FACTORY PLANNING
MAINTENANCE GREEN LOGISTICS
CONVERTIBLE LOGISTICS SYSTEMS
URBAN SUPPLY LOGISTICS NETWORK
CELLULAR INTRALOGISTICS MULTIMODAL LOGISTICS
© Fraunhofer IML

6. Lab: openID-Center
■ 1500m² laboratory for
industry and research
■ Showcase for all state-of-
the-art-technologies in the
supply chain
■ Integrated hard- and
software from partners
and sponsors
© Fraunhofer IML

7. Lab: Packaging Centre
■ Simulation of static, dynamic and climatic loads /
forces on packaging systems
■ 400 m² of testing area and 6 employees
■ 60 to 80 projects per year
■ High tech testing equipment
■ 4 climatic chambers
■ 2 vertical vibration tables
■ 1 tension / compression test machine
■ 1 horizontal impact test system
■ 1 precision drop hook and table
■ 1 vertical shock test machine
© Fraunhofer IML

8. Logistics can no longer be Managed
by the way
■ The days of being able to control logistics by
intuition are over.
■ Logistics has become an interdisciplinary,
highly complex discipline.
■ More than ever, logistics are called upon to
contribute to issues of the future.
■ It is important to recognize logistics as
technology and as a response to many social
issues.
© Fraunhofer IML

9. Creating tomorrow’s individuality
with 75% of today’s resources.
Individuality Efficiency

10. Key Issues for the Logistics of the Future
Environment and Transportation
Sustainability Management
Urban Supply Logistics-as-a-Service
Real-Time Flexible
Design Competence
Logistics Systems
© Fraunhofer IML

11. Sustainability in Logistics Networks
Social Economic Ecological
Working Fair trade Ressource
conditions efficiency Greenhouse gas
emissions
Education and Renewable
qualification energy
Noise emissions Land use
Waste
reduction
© Fraunhofer IML

12. Focusing Only on Production Technology
is Insufficient
High-value consumer and
investment products are
created in manufacturing
networks. 2nd tier 1st tier OEM
Transport Production 1 Transport Production 2 Transport Production n Distribution
Value Value Value
- Provide Pick
Store Pick Provide creation creation creation Store Pack
1.1 1.2 1.n
Fields of action in holistic Production boundaries:
consideration of processes Production technology Efficient usage of
from the supplier to the and processes
logistics resources
consumer
© Fraunhofer IML

13. Logistics Designs, Plans, and Executes
the Production Environment…
Production organization Supply concept
Production network
Factory building and layout Informationsfluss
WA
EM
Halle
EM 5 person
LDL LDL Kunde
EM Halle
Halle 4
EM BSF 6
VM/BSF Zulieferer Produzent Handel Entsorger
ProductLife
- -Chain
Halle 3/ A
VM VM
VM
M aterialfluss
WEGT WEKT
EM
Production and I&C
Halle
2 Halle 1
logistics facilities Logistics processes Process Modelling
Desktop
Desktop Web
Web Mobile
Mobile
Halle 7 Client Client Client
Client Client Client
Business Event
WA
Lagern
EXP CARNOT
EXP CARNOT Business Logic 11
Business Logic Business Logic 22
Business Logic
Kommiss- Deployment
Process Engine
Process Engine (EJB)
(EJB) (EJB)
(EJB)
Model Repository
ionieren JDBC JMS JCA JCA SOAP JEE Application Server
Messaging
Messaging ERP
ERP Web Service
Web Service
(e.g. Host)
(e.g. Host) (e.g. SAP)
(e.g. SAP) (e.g. PI, OMNI)
(e.g. PI, OMNI)
Verpacken Audit Trail
Database
...and determines its sustainability.
© Fraunhofer IML

14. Examples of the General Potential in
Logistics Networks
Global Supply Chain Local Supply Chain
■ Increase capacity usage through ■ New Supply Processes
bundling of transports ■ Reduction of noise and gas emissions
■ Improved ratio of emissions over ■ Resource Efficiency applying Lean
transport performance Concepts
■ Higher stock level required to absorb Perfor-
peaks mance
■ Less flexibility Position through
Scope of decisions ow n decision
■ Less express transports, e.g. air
cargo
Sustain-
■ Short lead times, low stock levels, but Costs
ability
high resource demand
■ Future Material Flow – Multishuttle
© Fraunhofer IML

15. Dynamics in Global Supply Chain
Operations
Supply chain Processes and resources Supply chain Markets
performance  Process quality events and risks  Demand dynamics
 Material quality  Process stability  Growth, Competition
 Supplier performance  Resource availability  Forecast errors
 Transports disruptions  Sales promotions
Dealer /
Dealer /
1st tier
1st tier LSP
LSP OEM
OEM LSP
LSP Customer
Customer
Wrong
delivery Capacity Natural disasters
shortage Machine Transport delays
Delayed vessels Rework breakdown
Material defects or air freight Customers
IT-breakdown  Order changes
Terrorism  Adhoc orders
Supply shortage Strike  Delivery date
Quarantined Machine Staff modifications
Accident
customs goods maintenance unavailability
s Traffic
© Fraunhofer IML

16. E²Log Project –
Sustainability Through Energy Efficiency
■ E²Log – Energy Efficiency in Logistics and Production
■ Analysis of effects of decision in production on the energy efficiency
of the entire supply chain
■ Integration of the objectives costs, performance, and energy
■ Development of methods and instruments for:
Long-term Short-/
medium-term
Strategic
Design
© Fraunhofer IML

17. Food Chain Management Today
<
■ Waste of food ■ More traffic
• About 50% of vegetables and fruits in • Higher delivery frequency
UK supermarkets have to be • Therefore more empty trucks
disposed
• Just in UK: 17 million tons per year
• Disposal cost: about 20 billion Euro in
UK Neither sustainable nor efficient nor effective
© Fraunhofer IML

18. Sustainable Food Chain Management
Packing
Rapid Testing
Sensor Technology
AutoID
Logistic
Warehousing Custmoer Service
© Fraunhofer IML

19. Carbon Footprint:
Volkswagen Amarok Production
SME
Bremerhaven
Harbour/ Harbour/ Wedemark
Airport Airport Salzgitter Production
Cross Dock Bremerhaven
CKD-Anchieta
Supplier
Santos
Pacheco
Buenos Aires
Santos
Buenos Aires
Hannover, Germany Pacheco, Argentina
© Fraunhofer IML

20. Carbon Footprint:
Volkswagen Amarok Production
■ Long and complex supply chain
■ Parts variety: approx. 650 different parts
■ Supplier variety: almost 400 European suppliers
■ Different keeping quality: depends on the material, parts (e.g. tires)
■ Obsolete materials: ramp-up and -down of parts
■ Limited supplier capacity, high market demand: no flexibility for
significant deviation from forecast
■ …
SME
Harbour/ Harbour/
Airport Airport Production
Cross Dock
Supplier
© Fraunhofer IML

21. Global Supply Networks with many
Locations cause Intransparency …
Capacity
Transport Localization (GPS) Production Progress
Utilization
Goods Receipt
Inventories
Goods Issue
Execution
Systems PPS
ERP
BDE
© Fraunhofer IML

22. Real-Time Logistics: Fast Identification
and Transparency
■ Challenges:
■ information must be available on time in full
■ find standards for cross-company implementation of Real-Time
Auto-ID-Technologies (e.g. RFID)
■ enable intelligent information sharing, execution and event handling
© Fraunhofer IML

23. A new Software Approach to Evaluate
Global Ecological Sustainability
Supply
Chain
Monitoring
Demand Supply
Capacity Chain
Planning Simulation
Transport
Planning
eLog@istics Award 2011
combining ECOnomic & ECOlogic objectives
in Logistic Assistance Systems
© Fraunhofer IML

24. ECO2LAS: Carbon Footprint for the
Supply Chain
© Fraunhofer IML

25. Sustainable Resource Efficiency:
BETA Project at FIAT Betim, Brazil
■ Initial Situation:
■ FIASA (Fiat Automoveis SA): 3.150 cars/da
(14 models)
■ FPT (Fiat Powertrain): 3.300 engines +
3.500 transmissions
■ LSPs for all in-plant-logistics for over 15
years
■ BETA Project (started in 02/2012):
■ Insourcing of all logistics activities in FIASA
Security
and FPT
■ Goals:
World ■ Better quality of logistics processes
Equip- Lean
ment Class Logistics ■ Improve security
Logistics
■ Reduce Logistics Costs
IT/WMS
© Fraunhofer IML

26. Sustainable Resource Efficiency:
BETA Project at FIAT Betim, Brazil
■ Structuring and mapping of Logistics
processes
■ Transparency on current logistics
processes
■ Identification of cirtical procedures
■ International Bench Marking (Best
Practices)
■ Define short-, medium- and long-term
Receiving Storage
Line improvements
Feeding
Truck
entry
■ Develoment and mapping of ToBe-
Load
Check
Goods
receipt
Proecesses
Empties
load
Label
print
■ Document new standard processes
Truck
exit
Buffer ■ Roll out of best practices in all shops
Line
■ Keep knowledge of processes
Storage
demand
Material
Picking
Delivery
■ Facilitate continuous improvement
© Fraunhofer IML

27. Sustainable Noise Emissions:
Urbanization meets Factory
Current Plant and Supplier Concept
■Minimize stock levels and coherent lot sizes through in time supply
■Just-in-time supply of components with reduced delivery quantity and higher
frequency
© Fraunhofer IML

28. Sustainable Noise Emissions:
Evaluation of Future Scenarios
■ Analyze of different distance clusters and supply concepts to find
solutions which reduce noise and gas emissions and guarantee reliable cost
efficient supply.
Standard Supply
Palets, Boxes (GLT)
Small Boxes (KLT)
Special Supply
Seats
Tires
Engines
Vehicles
Fully Build Up Units (FBU)
OEM Ext. Warehouse and Cross Dock
DC
Direct nesxt to plant Distance Cluster 1 (DC 1) DC 2
3
© Fraunhofer IML

29. Sustainable Noise Emissions:
a new Paradigm
Distance Cluster 3
■ Simulation based
Supplier Locations
study of different future
Distance Cluster 2 scenarios (demand,
structure, processes).
Distance Cluster 1
Highway
■ Evaluation of
Border transports, gas and
noise emissions and
identification of
sustainable supply
Urbanized Area
Ext. Warehouses
(e. g. Cross Docks,
strategies.
■ Identification of a Road-
OEM
Map for future supply
chain management.
Distribution Route
© Fraunhofer IML

30. Multishuttle Move – a new Material Flow
Paradigm inside the Factory
Diese Entwicklung wurde gefördert durch:
© Fraunhofer IML

31. Diversity of Logistics – Sustainability is a
mayor Issue!
© Fraunhofer IML

32. Logistics: connecting ...
... and communicating!
Dr.-Ing. Michael Toth
Muito obrigado
pela atenção!
phone: +49 231 9743 169
fax: +49 231 9743 234
email: michael.toth@iml.fraunhofer.de
Fraunhofer IML
© Fraunhofer IML