Fabbrica Futuro Marco Cesari Operations Manager Bonfiglioli Riduttori Mobile and Wind Solutions Business Unit Bologna, 19.03.2014 Agenda • Bonfiglioli Riduttori overview • Mobile and Wind Solutions production sites and product lines • Proud of our Customers • Headquarters Shopfloor (Forli) • P&L trend • How did we do • P&L main contribution • What’s next 2 Company Overview The Bonfiglioli Group has been working according to Business Unit logics for years in order to develop the best service and innovation and to offer the most suitable products and business models of the supported areas. Today the Company consists of 3 Business Units and 2 Division. 3 Business Unit Mobile & Wind Solutions 4 Business Unit Mobile & Wind Solutions Headquarters of the BUMWS Manufacturing Site/Engineering FORLÌ Site Area Real estate:85.000 m2 Building: 36.000 m2 Total No. of employees 620 White collar: 164 Blue collar: 456 (upd. Dec. 2013) 5 Local for Local: India BONFIGLIOLI TRANSMISSION PVT LTD. MANUFACTURING SITE/ENGINEERING CHENNAI – INDIA Site Area Real estate:26.820 m2 Building: 16.150 m2 Total No. of employees 415 White collar: 219 Blue collar: 196 (upd. Dec. 2013) 6 Local for Local: China BONFIGLIOLI DRIVES CO., LTD. MANUFACTURING SITE QINGPU – CHINA Site Area: 10.000 m2 Completed the purchase of land for new building with BUINS – Project for 22.000 sqm building Total No. of employees 77 White collar: 49 Blue collar: 28 (upd. Dec. 2013) 7 Product lines 300 series Multipurpose planetary drives 500 series Concrete mixer drives 700C series Track and road roller drives 700CK series Excavators track drives 600 series 700T series Wheel drives Slew drives 800 series 700TK series Winch drives Excavators Slew drives 8 Concrete Mixers 9 Agriculture, Forestry & Snow Equipment 10 Road Construction 11 Skid Steer Loaders, forklifts and more 12 Aerial Platforms, Scissors Lifts, Telescopic elevators 13 Excavators 14 Miniexcavators 15 Crawler Undercarriages Caterpillar Industrial Products, Inc. Belgium A Titan Europe Plc Company 16 Mobile crushers, screeners and shredders 17 Soil Drilling 18 Soil Drilling 19 Tower Cranes, Mast climbing platforms 20 Mobile Cranes 21 Marine equipments, Cranes, Winches and Hoisting 22 Marine equipments, Cranes, Winches and Hoisting CONCRANE 23 Wind Turbines 24 Wind Turbines 25 Shopfloor Walking through Trasmital – Gear cutting PLANETARY GEAR PRODUCTION 27 Walking through Trasmital – Heat treatment INDUCTION HARDENING TREATMENT BEARING OUTER RACES HARDENING 28 Walking through Trasmital – Machining Area KLINK BROACHING MACHINE FOR RING GEAR AND HOUSING GEAR MANUFACTURING RING GEAR BROACHING 29 Walking through Trasmital – Gearboxes assembly 700C – 700CK SERIES 30 Walking through Trasmital – Automatic Warehouse 31 BT Turnover M€ 350 300 250 200 150 100 50 0 2004 2005 2006 2007 2008 2009 2010 2011 2012 32 BT Investments 20,0 17,5 15,0 12,5 10,0 7,5 5,0 2,5 0,0 2004 ACT 2005 ACT 2006 ACT 2007 ACT 2008 ACT 2009 ACT 2010 ACT 2011 ACT 2012 ACT 33 2008: results 2008: EBITDA and Inventory Inventory (K€) Turnover (K€) 2008 Inventory Turnover 35 P&L Trend BT Financial performances 2008-2012 – FICOS – K€ 8,0% 6,0% 300.000 4,0% 2,0% 200.000 0,0% -2,0% -4,0% 100.000 -6,0% -8,0% -10,0% 0 2008 2009 Ebitda 2010 consumi costi ind.li 2011 altri costi 2012 sales *misurazioni Vs 2008 37 How did we do? Scope PLANT SCM ACQ 39 PLANT Plant reenginering SCM RIM 2 K04 G02-G04 Painting K01 B G05 R05 U07 G06 TS19 Test Lab U04 TT07 U06 TS16 U08 FPS TT06 TC25 O10 TT09 TS03 TC23 TC20 I WH TT02 L05 H04 I TT11 TC22 TC19 TC16 TC11N TC18 RMKK RIM 1 40 ACQ PLANT i.e. TC 23 assembly workshop SCM 606W SERIES Before workshop After workshop 41 ACQ PLANT Main KPI’s SCM MACHINING ASSY OEE (%) Efficiency (%) 100 90 80 70 60 50 40 30 20 10 0 2010 2011 ACQ 2012 2013 86 84 82 80 78 76 74 72 70 68 66 2010 Cycle Time x Qty: Overall reduction (hours) 2011 2012 2013 Cycle Time x Qty: Overall reduction (hours) 5.000 14.000 12.000 4.000 10.000 3.000 8.000 2.000 6.000 4.000 1.000 2.000 0 0 2010 2011 2012 2013 2010 2011 2012 2013 42 PLANT Plant KPI’s SCM ACQ Operations KPI: Production Dept and Accidents at work Manufacturing Performances Assy Efficiency/OEE id description Cycle Time Reduction 1 OEE LM 3 Safety Indicators AREA PRODUZIONE color code base algorithm EFFICIENCY LM unit TGT 2012 range 1 range 2 ytd actual OK IF ytd actual W Nr. Hours of routing x quantity produced/available machine hours % 74% 1% 5% 73,5% 73,0% + 1 1 W Nr. Hours of routing x quantity produced/available direct workers hours % 112% 1% 5% 105,8% 113,4% + 0 1 83,7% + 1 1 - 2 0 Operations KPI-2012: Quality Control 5 EFFICIENCY MTG W Nr. Hours of routing x quantity produced/available direct workers hours % 79% 1% 5% 79,8% 7a ABSENTEISM MACHINING M Not presence hours assy (escluso ferie) % 8% 1% 3% 10,7% 13,3% AREA CONTROLLO QUALITA' 7b ABSENTEISM ASSY 10 1 FREE PASS ASSY TIME CYCLE REDUCTION 11 MACHINING TIME CYCLE REDUCTION 17 Controlli Accettazione Forniture Efficienza Collaudo Accettazione M 2 SKIP M 3 CAMPIONATURE [controlli lenti] M 4 COLLAUDARE [controlli veloci] M 5 EFF TOT Collaudo Accettazione M NUMBER OF DAYS OF ABSCENCE FOR ACCIDENTS Efficacia Montaggi 8 BUONI AL PRIMO COLPO unit range% 1 1% hrs 6% -3200 7,24 1% 5%6,35 1% -1700 6% 71,19 5% 10,00 1%reliability 6% Equipment 14,22 14,80 (S S ) (S S ) 75,00 FREQUENCY INDEX SEVERITY INDEX 9a color code OK IF = ± 1% - 1% 5% 101,01% 110,49% + 1 unit TGT 2012 range 1 1% 5% gg 1% 365 5% gg 0 hrs 0,50 1% 6% FTE (FULL TIME EQUIVALENT) Mrobot N. -addetti fuori= lineaT MachinesDow ntime / Number # of dow ntimes 0,51 2d Turning w ithout MTTR equivalenti impiegati per riparazioni M MTTR ON REPAIR 1% 6% S M S Nr. Infortuni nel periodo considerato / Nr. Lavoratori anno*1000 30,00 S T MachinesWorking / Numberminof dow ntimes M - MTBF Tempo medio di esecuzione del benestare Working centers M d'officina MTBF = 11a 3b Working centers M - MTTR N.° totale benestare d'officina mese M MTTR = BENESTARE D'OFFICINA S nr nr 1% 0 # of dow ntimes T MachinesDow ntime / Number S 11b Gear cutting cells MTBF medio di esecuzione del benestare M d'officina M - Tempo min 50,00 MTBF = bloccante T MachinesWorking / Number of dow ntimes 11c 4b Gear cutting cells MTTR M MTTR = M - N.° totale benestari d'officina mese bloccanti S T MachinesDow ntime / Number # of dow ntimes - 14 5a Grinding machines - MTBFupdated EO Feb MTBF = S T MachinesWorking / Number#of dow ntimes 35 5% 15% 5b Grinding machines - MTTRgood if actual >= TGT-range M 1 MTTR = W N.° 8D PENDENTI IN CARICO PRODUZIONE B6 S T MachinesDow ntime / Number # of dow ntimes 14 5% 15% 6a Pinion toothing machines - MTBF S T MachinesWorking / Numberggof dow ntimes 80 5% 15% 6b Pinion toothing machines - MTTR 5% 15% 8D PENDING 14a 15 LT 8D W M M N.° 8D PENDENTI A CARICO DEL PLANT M MTBF = Tempogood medioifdiactual chiusura 8D a carico <=degli TGT+range 1 del Plant S 1% hrs hrs 25,0 91,21 0,9 0,51 85,0 1,110,9 5% -R2 0,22 3 708 0,6 1 6 + 1 OK IF ytd 1 OK IF 1 22,8 20,5 + 1,3 1,1 708 actual color code 1 ytd42 actual + 0 - act 1 0 ytd 2 1 1 2 1 0 - 30,6 1 - + - - 1 - 00 0 1 2 - 88,90,78 -0 + 11 1 hrs 0,600,9 0,85 0,3 0,6 - -0 - 00 0 hrs 28,68 25,0 25,95 3 6 -1 + 11 1 hrs 3.264 0,8 0,3 226 0,6 1,3 - - 0 2 hrs 34,74 165,0 3 27,02 6 59,5 -1 + 11 0 hrs 8230,8 0,3 62 0,6 2,6 - - 0 0 YTD 6 +R1 36,3+R2 26,1 2 + 0 0 0 1,6 1,1 1 - 2 1 0 63,9 - + 1 0 1,5 - - 0 0 0,3 37,56 hrs -R158,0 43 hrs hrs ACT 3 37 0,8 0,3 0,6 117,0 3 6 0,7 0,3 0,6 15 110 MTTR = S T MachinesDow ntime / Number of dow ntimes hrs 0,9 7c Induction hardening w ithout robot - MTBF M MTBF = S T MachinesWorking / Number of dow ntimes hrs 7d Induction hardening w ithout robot - MTTR M MTTR = S T MachinesDow ntime / Number of dow ntimes 8a Hobbing machines - MTBF M MTBF = S 8b Hobbing machines - MTTR M MTTR = S N.° Avvisi con addebito 160 € per scarto a fornitore 88,95 0,3 6 + actual 6 0,83 M M 3 1 color code 0,89 3 Induction hardening w ith robot - MTTR MTTR = 108,27% 0 hrs 0,32 85,0 7b 16 EURO 160 M Tempo medio di chiusura degli 8D in carico Produzione B6 121,57% range range 42 1 2 2 27,88 0,6 7a M ytd 0 0,21 T MachinesDow ntime / Number of dow ntimes gg 80 good if TGT-range 1=< actual <= TGT+range 1 Induction hardening w ith robot - MTBF M MTBF = S T MachinesWorking / Number of dow ntimes 15a range 2 0 5% 4a updated W17 2012 100,75% hrs 5%0 MTBF = T MachinesWorking / Number of dow ntimes Nr. Infortuni nel periodo considerato*1000000 / H. effettive lavorate 5% 101,52% TGT unit 1% nr T MachinesWorking / Number of dow ntimes 3a 0 100% S 11 ± 1 T MachinesDow ntime / Number of dow ntimes min 1 - S S -85 2,97 FTE (FULL TIME EQUIVALENT) M N.MTTR addetti impiegati per in linea # 0,51 Nr. equivalenti Giorno persi*1000 / H.rilavorazioni effettive lavorate 2b Turning w ith robot -M M MTTR REWORK IN LINEA = T MachinesDow ntime / Number of dow ntimes MTBF = + 7,34 5%2 M ± 11 6% S Tempo di fermo for isole del MTG dovuto a Riparazioni in isola MTG, Materiale M Number corrective actions Turning w ith robot -Difettoso, MTBF Ripetizione Collaudo + 1 1% 1% gg MTTR = -287 avg 0 YTD -326 9,00 0,50 M M 75,87 -3591 0 min weekly data (base = W) color code OK IF = - YTD 1% M INDICE DI INCIDENZA color code OK IF = + Number of abscence for accidents Broaching machines - MTTR 10 RIPARAZIONI FUORI Mrobot Tempo impiegato per Riparazioni riduttori 2c LINEA Turning w ithout - MTBF M scartati 10a monthly data (base = M) M Riduttori buoni al primo collaudo finale avg 1% 100 2a M hrs range 8% 2 3% actual 14,2% OK IF17,1% actual- TGT 2012 6,00 Suddivisione per tipo di controllo delle Entrate Materiale % M TCi NEW Controllo) TCi OLD * Q.ty produced % Free Pass (Nessun Suddivisione per tipo di controllo delle Entrate Materiale % M Stock QTC TCi OLD * Q.ty produced % Skipi NEW Suddivisione per tipo di controllo delle Entrate Materiale % Operations KPI: Production % Stock Q Controlli Lenti Suddivisione per tipo di controllo delle Entrate Materiale % % Stock Q Controlli Veloci AREA SICUREZZA Efficienza avanzamento del totale Entrate Materiale Stock Q escluso Skip % (lenti +algorithm veloci): numero di lotti entrati da avanzare per ora di MOInd impiegata base % 1b NUMBER OF DAYS FOR CORRECTIVE ACTIONS 9 RILAVORAZIONI IN LINEA Quality Control Maintenance Indicators: 13 14 Machines MTBF 15 Machines MTTR 16 M Not presence hours assy (escluso ferie) base Description Acronym MAINTENANCE AREA EFF V Collaudo Accettazione 6 M Efficienza avanzamento delle Entrate Materiale Stock Q Controlli Veloci % 100% (sottoinsieme controlli veloci) id description base algorithm NUMBER OF DAYS WITHOUT ACCIDENTS M Number of days without accidents EFF L Collaudo Accettazione 7 M Efficienza avanzamento delle Entrate Materiale Stock Q Controlli Lenti % 100% (sottoinsieme controlli lenti) 1a Broaching machines - MTBF M MTBF = T MachinesWorking / Number of dow ntimes Efficienza Sala Metrologica 12 description Capacità di Reazione ai CLAIM Cliente id id Avvi si 160 Quality Control: Incoming Checks KPI Process Control KPI 8D Customers KPI color code hrs 82 12 91 93 1,50,00 1,9 0,00 - 32,6 - - 2 0 0 1 6 13,5 31,3 + 0 0 0,3 0,6 1,2 1,1 - 1 2 50,0 3 6 39,1 77,9 + 1 0 hrs 0,9 0,3 0,6 1,2 0,0 - 1 2 T MachinesWorking / Number of dow ntimes hrs 215,0 3 6 164,2 - + 1 0 T MachinesDow ntime / Number of dow ntimes hrs 1,0 0,3 0,6 1,1 - - 0 1 # hrs - 50,0 732 3 29 43 PLANT Planning method management SCM Estrazione dati W41 Analizzati Item con Fabbisogni + consumi sul 2009 Item a costanza e costo elevati: -N° item: 373 (5%) Item a basso costo: -N° item: 1629 (24%) Item a bassa costanza ed elevato costo: -N° item: 953 (14%) Item a bassa costanza: -N° item: 3925 (57%) 44 ACQ PLANT Suppliers orders management Politiche di approvvigionamento 2009 % a valore CA - ordine chiuso 76% CA - Ordine aperto 24% N° item gestiti in CLF/CLP Politiche di approvvigionamento 2011 % a valore CA - ordine chiuso 39% CA - Ordine aperto 61% N° item gestiti in CLF/CLP SCM LT medio pesato (gg/ lav) 20,92 3.804 LT medio pesato (gg/ lav) 14,41 3.325 Delta politiche 2011 vs 2009 CA - ordine chiuso CA - Ordine aperto N° item gestiti in CLF/CLP % a valore -37% 37% LT medio pesato -31% -13% Ex: 2T706T3191A01 da 13 a 9 settimane Ex: 2T255608241A da 14 a 11 settimane (606 BOMAG) 45 ACQ UNIT VALUE LT Deployment – 715C – (2012 Vs 2008) PLANT SCM 2012 2008 -25 % vs 2008 46 ACQ PLANT The evolution Capacity Dashboard SCM ACQ YEAR AREA WC U.M 2009 Plant No detail Euro/d 2010 Assy Assy WC Pcs/d Today Assy/Machining Assy + Machining WC h/d Tomorrow ALL Supplier + Assy + Machining WC h/d Details Requirement Capability Dissaturation Oversaturation 47 Levelling process: from weekly to daily bucket scheduling PLANT SCM 48 ACQ Assembly line refilling: Routes summary Projects PLANT SCM ACQ 1 2 3 CL1 CL1 3 standard different runs have been developed to supply several supermarkets of assembly lines.The refilling is done by a tractor and two trailers. 49 PLANT SCM KPI’s SCM PLANNING Sales Planning Order Management Turnover BUMWS Stock Service Level. id name unit TGT 2013 range 1 range 2 avg last 25ww actual OK IF color code 13 ITEMS ON DELIVERY PLAN W # items on delivery plan vs items planned, for direct customers (BRT excluded) % 18% 5% 10% 21% 22% + 1 25 ITEMS PLANNED % % items = last 20% of the volumes % 77% 2,5% 5% 83% 84% - 0 id name unit OK IF color code 1 ORDER INTAKE W Sell-In value order intake (BUMWS) 2 ORDER id name CANCELLATIONS W 23 PORTFOLIO GROWTH W 3 4 22 5 id 14 -Inbound OTD -LT -Lot Size Plant Stock monitor Automatic Warehouse base TGT 2012 range 1 range 2 avg last 25ww actual PLANNING M€ 5,0 1,00 2,0 3,8 4,9 Sell-In value orders cancelled base(BUMWS) description M€ 0,0 0,13 unit TGT 0,25 2012 range 0,1 1 range -0,8 2 open orders B6 current week vs last week M€ 0,0 -0,50 -1,00 -0,4 0,2 description 10 0 OK IF color code M see document "APO customization in B6_v4" % 0% 0,5% 2,0% 29% 39% - 0 M see document "APO customization in B6_v4" % 20% 1,0% 3,0% 34% 30% - 0 12 MAPE MASTER PLAN 7-9 M see document "APO customization in B6_v4" 20% avg 2,5% range last 2 25ww 5,0% 28% color 48% - 0 M see document "APO customization in B6_v4" 38% - 0 ± 0 100% 100% 1 -0,7 ± + 2 5,0% 100% + 1 100% + 1 85% + name base TURNOVER description MAPE MASTER PLAN unit WEEKLY SELL-IN W Sell-In turnover finished goods (B6) »»»»»» rif = BDG M€ TURNOVER 24 PLANT REACTIVITY 1-4 M see document "APO customization in B6_v4" MONTHLY SELL-IN M Sell-In turnover vs BDG finished goods (B6) M€ TURNOVER VS BDG 25 PLANT REACTIVITY 5-6 M see document "APO customization in B6_v4" MONTHLY SELL-OUT M Sell-Out turnover vs BDG finished goods (BUMWS) M€ TURNOVER VS BDG 26 PLANT REACTIVITY 7-9 M see document "APO customization in B6_v4" TURNOVER M MEDIAmese [(max-media)/media of weekly turnover B6] % STABILITY TGT 2012 % range 1 % 5,0 0,0 20% Procurement 0,50 100% 0,50 % 0,0 7% 0,25 Supply Chain KPI% 1,00 100% 3,00 5,00 % 100% 5% 10% 0,5% 3,3 5,0% -18,8 2,5% -27,3 2,5% 32% M see document "APO customization in B6_v4" % 100% 2,5% 27 PLANT REACTIVITY id description M see document customization in B6_v4" STOCK base "APO algorithm % 100% 2,5% unit 38 name RESPECT OF FLEXIBILITY base description1-4 M see document "APO customization in B6_v4"unit range % 1 range avg last 100% 2,5% 2 25ww 39 RESPECT OF FLEXIBILITY 5-6 % 100% 100% 0,12 2,5% 9,6 1 M Stability Procurement Plan (Closed Order) stock B6 vs BDG EOY M W N° Fixed Codes* / n° Total Code (forecast + 6 w vs +3 w) see document "APO customization in B6_v4" M€ 49,0 0,63 1,25 % 2,5% 40,5 OK IF 2,0% 3,5 PLANT REACTIVITY M10 TGT 2012 actual 2,5% 23 code 30% ± -1,2 5,0% 98% - 56% 5,0% 100% 4,4 % 0,06 37 RESPECT OFMFLEXIBILITY M10 vs BDG M stock subsidiaries EOY see document "APO customization in B6_v4"M€ 43,4 % 0,63 100% 1,25 2,5% 57,4 96,8 1,31 % 2,6 100% 107,5 2,5% 4,0 0,25 0,5 % 95% Inbound (Range Delay ) W "APO Rangecustomization % Weekly Purchase in delay (Open Order% + Closed Order+ see document in order B6_v4" 95% CLP) SERVICE 2,7 2,5% 3,7 5,0% % 2,5% 5,0% See 40% 2,5% 5,0% 41% 3.1 Supplier Delay days of stock after paintingW (weekly seeaverage) document "APO customization in B6_v4"gg 43 STABILITY 3.2 10% W 44 STABILITY 20% W see document "APO customization in B6_v4" % 95% % M€ 0 TGT range 99% range Avg. 5,0% 91% actual + 2012 1 2 color YTD 5,0% OK73% 68% actual IF + code 100% 6% 10% 52% 20% 5,0% 88% 91% + 40,5 1 - RESPECT OFMFLEXIBILITY 7-9 M see document "APO customization in B6_v4"M€ stock BTPL vs BDG EOY 2 Stability Procurement Plan (Open Order) W N° Fixed codes * / n° Total codes Inbound ( Trend in Value ) W see document "APO customization B6_v4"M€ Value purchase orders inindelay 100% 1 40 STOCK STOCK AFTER W 42 STABILITY 5% PAINTING 17 18 + MAPE MASTER PLAN 5-6 STOCK BUMWS STOCK vs BDG M 41 VS BDG RESPECT OFMFLEXIBILITY 9 21 1 1 actual MAPE MASTER PLAN 1-4 19 7 8 ± avg last 25ww 11 15 id »»»»»» rif = BDG 10 13 Procurement description ORDER MANAGEMENT id APO Planning rules monitor APO Order Management base 5,0% 9,6 base 4.1 description 4.5 M PORTFOLIO DEPTH 49 NOT CONFIRMED ORDERS 0 -0 0 DETAIL 35% + 0 35% + 0 2,00 0,50 -80% 1,0 107,5 5,0% -40% 2,3 0 0 1 Q (qty shipped in Wn with confirmed date Wn or Wn+1)/(qty on order in Wn+qty 47 DELIVERY PLAN DECREASE INSIDE CUT-OFF W see document "APO customization in B6_v4" % ON TIME W shipped with confirmed date Wn+1) 48 + + 0 94% TGT range range avg last color N° Codes with needs / Total codes with unitneeds ( based on the type of actual OK IF 2012 1 2 25ww Seecode DETAIL % supply) W delay of finished goods without commercial block(value)ORDER MANAGEMENT M€ 1,0 0,25 0,5 6,4 5,1 0 Value codes with needs / Total Value codes with needs (based on the DELAY avg See DETAIL 4.2W delay of finished goods with commercial block(value) Q % range M€ 0,0 0,13 0,25 4,4 3,0 0 TGT range type of supply) id name base description unit last actual OK IF 2012 1 2 # 25ww W # orders rows in delay not blocked 50 based10 25 of 100,8 57 1 Lead time weighted average (Supplyrighe average time on the value COMPONENTS DELAY 4.3 Supply Method Q "APO customization in B6_v4" gg 30100 5 29010 23,3 45 CUT-OFF W see document PC 50 297 the codes with needs) W value in delay (orders not blocked) M€ 0,4 0,1 0,2 0,2 0,1 1 52 CUT-OFF % on ALERT W see document "APO in B6_v4" 0% 5% 10% 20% 0 22% Cover customization Bath weigh (N° Cover day average on the% value code 903,1 W MAX(distance between today and oldest open order) gg based49 7 of the14 994 4.4 Q gg 5 2 5 7,2 DAYS OF DELAY with needs) distance today and date document in which the"APO cumulative volume in delay 46 PLAN INCREASE INSIDE between CUT-OFF W the see customization in B6_v4"gg PC7 10 W 14 14 84,6 6320 0 -147 1.057 = 95% name 0 1 34% -99% 6% - 10% 5,0% 57,4 +0 0 75% 73% 0 82% color code 0 + 78% + 2,0 + 92% 100% 0 OK IF0 W 5 Leveling Incoming Material 6 N° codes for each Planner W Cover index in day (warehouse turnover ratio)95% PC 2,5% Incoming Material Value ( real) / Weighted average days# to fulfill W purchase order backlog on W of competence see document "APO customization in B6_v4" PC see document "APO customization in B6_v4" Q N° codes with needs/ N° planners (only GEM) 5% gg 10 31% 17 - 5 100% 5% # 1000 100 50 100 1 0 2 - 0 -0 2 10% 101% + 135% - ±0 0 150 657 - 0 13 % -0 41,3 - 20 5% ±148 36 10% 34% 3 color code 269 38,5 0 588 12 198 0 Capacity Dashboard 50 ACQ Purchasing Dept. main developed projects and activities PLANT SCM • Savings Yearly Project • Direct Materials • By committing business to Suppliers • By negotiating materials through Value Analysis • By negotiating prices with base material prices • Indirect Materials • By reducing Suppliers base and defining rebate agreements based on business volume • SCM collaboration • Lead Time reduction* • Flexibility increase • Supplier OTD increase • Working capital reduction* • Frame contracts with Strategic Suppliers at BU level 51 ACQ PLANT Purchasing KPI’s SCM PURCHASE KPI unit TGT range range color avg YTD actual OK IF 2013 1 2 code PPM 5000 1,0% 1,0% 5925 6.004 - 0 PPM 1000 1,0% 1,0% 2252 2.376 - 0 PPM 200 1,0% 1,0% 253 352 - 0 PPM 1000 1,0% 1,0% 845 899 - 1 No of PO raw delivered on time/ No PO raws % 98% 0% 0% 70% 69% + 0 monthly PPV= ∑(Current Price -STD price ) X QTY /Supplier spend % -1,7% 0,0% 0,0% -2,54% -2,75% - 1 SUPPLIER OVER ALL RATING monthly SOR= PPVX30% + OTD X30% + PPM x40 % % 100% 35% 0% 80% 80% + 1 9 CONQ (month) monthly ∑ Suppl. CONQ (month) k€ 100 1,0% 1,0% 50 70 - 1 10 CONQ YTD monthly ∑ Months CONQ k€ 1000 1,0% 1,0% 208 208 - 1 11 % CONQ monthly CONQ_YTD / SUPPLIER SPEND_YTD % 1,0% 0,0% 0,0% 0,49% 0,59% - 1 12 RCONQ monthly Reinvoiced CONQ / CONQ ( updated N-3 months) % 90,0% 0,0% 0,0% 80,4% 80,4% + 0 15 %NVSS monthly ∑ subcontracting parts spend / ∑ supplier spend % 4% 0% 0% 5,3% 5,82% - 0 18 Payment terms six months WAPT-Weighted Average Payment Terms (days) gg 110 0 0 105 105 + 0 id description base 1 PPM raw parts monthly 2 PPM finished parts monthly 3 PPM commercial parts monthly 4 Total PPM monthly 5 OTD monthly 6 PPV 7 algorithm (No of scraps/ No of parts delivered)x 1000K - 6 months rolling (No of scraps/ No of parts delivered)x 1000K - 6 months rolling (No of scraps/ No of parts delivered)x 1000K - 6 months rolling (No of scraps/ No of parts delivered)x 1000K - 6 months rolling 52 ACQ P&L main contributions Project savings: 2011-2012 breakdown € 5.000.000 € 4.500.000 € 4.000.000 € 3.500.000 € 3.000.000 € 2.500.000 € 2.000.000 € 1.500.000 € 1.000.000 € 500.000 €0 gen-11 mar-11 mag-11 lug-11 set-11 nov-11 gen-12 mar-12 mag-12 lug-12 set-12 nov-12 Quality control gen- feb- mar- apr- mag- giu- lug- ago- set- ott- nov- dic- gen- feb- mar- apr- mag- giu- lug- ago- set- ott- nov- dic11 11 11 11 11 11 11 11 11 11 11 11 12 12 12 12 12 12 12 12 12 12 12 12 € 0 € 0 € 0 € 0 € 0 € 0 € 15. € 20. € 36. € 50. € 63. € 70. € 82. € 92.€ 110€ 121€ 132€ 143€ 155€ 157€ 167€ 176€ 184€ 184 Indirect purchase € 0 € 0 € 0 € 0 € 0 € 0 € 5.7 € 9.8 € 20. € 32. € 44. € 63. € 90.€ 121€ 164€ 198€ 248€ 295€ 342€ 357€ 387€ 420€ 452€ 476 Logistics € 0 € 0 € 0 € 0 € 0 € 0 € 24. € 43. € 73. € 92.€ 117€ 155€ 189€ 221€ 242€ 276€ 302€ 332€ 366€ 423€ 462€ 493€ 538€ 591 OEE Machining € 0 € 0 € 0 € 6 € 0 € 21. € 35. € 43. € 63. € 82.€ 100€ 108€ 126€ 133€ 151€ 167€ 189€ 209€ 224€ 229€ 241€ 252€ 261€ 265 Equipment/Manpower € 0 € 0 € 0 € 1.3 € 7.5 € 13. € 18. € 21. € 38. € 52. € 74. € 97.€ 122€ 150€ 190€ 238€ 296€ 345€ 397€ 410€ 446€ 482€ 508€ 526 Assy € 39. € 93.€ 160€ 214€ 270€ 293€ 357€ 391€ 512€ 620€ 753€ 859€ 948€ 1.0 € 1.1 € 1.3 € 1.4 € 1.6 € 1.7 € 1.7 € 1.9 € 2.0 € 2.1 € 2.1 Lean& Green € 4.1 € 13. € 26. € 32. € 49. € 66. € 78. € 95.€ 110€ 130€ 150€ 164€ 177€ 200€ 206€ 224€ 237€ 253€ 268€ 289€ 305€ 325€ 341€ 363 GRAND TOTAL € 43.€ 106€ 187€ 248€ 328€ 394€ 535€ 625€ 856€ 1.0 € 1.3 € 1.5 € 1.7 € 1.9 € 2.2 € 2.5 € 2.9 € 3.1 € 3.4 € 3.6 € 3.9 € 4.1 € 4.4 € 4.6 54 Productivity Trend Pz /ora lav.ta 0,80 0,75 0,70 0,65 0,60 0,55 0,50 0,45 0,40 0,35 0,30 I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM 2008 2008 2008 2008 2009 2009 2009 2009 2010 2010 2010 2010 2011 2011 2011 2011 2012 2012 2012 2012 €* /ora lav.ta € 900 € 800 € 700 € 600 € 500 € 400 I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM I° TRIM II° TRIM III° TRIM IV° TRIM 2008 2008 2008 2008 2009 2009 2009 2009 2010 2010 2010 2010 2011 2011 2011 2011 2012 2012 2012 2012 55 Direct Material Saving YOY* % 100,00 99,50 99,00 98,50 98,00 97,50 97,00 96,50 96,00 95,50 2010 2011 2012 * On average yearly cost 56 PLANT BT Inventory vs Turnover K€ 2008 2009 SCM 2010 2011 2012 Turnover 35.000 90.000 80.000 ACQ Turnover Inventory 30.000 70.000 25.000 60.000 50.000 40.000 20.000 15.000 30.000 10.000 20.000 5.000 10.000 0 0 57 57 What’s next? INSANITY: doing the same thing over and over again and expecting different results Albert Einstein THANK YOU!
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