Italie onsite saint gobain

Italie onsite saint gobain

Saint goblain in Italie: 42 millions in stocks in Europe

Italie: Lead time average 79dd

What is average lead time to fix order from the customer: 5dd

Need of customer: 5d but for customer is 79dd

Italy/poland/spain/france!

Poland : orders and deliveries are made manually (sent to supplier via mail) - calling customer service at suppliers. ⇒ how to know how much to buy? based on BOM and forecasts. contact with planning.

Replenishment: One priority (reduce sotck but keep the service level high)

Need to keep stock for transfers (huge components for this case). transfer is a headache. components on the VW Golf?

In poland the supply chain manager seems doing repetitve task, everyday on excel!

A lot of transfers in between plants and countries ⇒ Keep much more components. NO VISIBILITY on each other. Working in silos.

Consumption is higher than planned in SAP.

A la mano: Safety stock report racking results on paper !! daily report!!

How have it been calculated ? ⇒ lead time. Safety stock placed with best feelings. Poland think it is right. Don"t know who made the decision of the safety stock.

Who defined the safety stock ? ⇒ don't know who defined. Putting a random value for safety stocks. ⇒ potential to do better.

Spain : safety time. Put a days of coverage x lead time. Do it case by case out of SAP.

Poland : From 1 to 10 the way you are working, score? ⇒ don't know

Spain :

3 plants. 32 - 20 - 89 suppliers.

230 component(77 assignement) - 84 component (35 ass.)- 233 components(39 ass.)

Current stock status : 7M€ stocks - 30k units. Glass 77%, 33% components.

Components ⇒ going from 3.9M to 7M BRF. 2M€ in consignment.

Main problems:

⇒ lack of information about the parameters (MOQ, lead time, shelf life, storage cond., ...)

⇒ Changes unexpected in demand

⇒ Lack of accuracy on EOP dates

⇒ Unreliable suppliers

⇒ Lack of information about delivery status

⇒ Prod plan outside of SAP

⇒ Lack of information about delivery status (shipment notification, follow up...)

France : Thourrote, Aniche, Noyon, Neuilly en Thelle (DC), Danjoutin (DC)

stock value: 3.6M

1.5M glass

0.6 conncetors

0.4 Trim

0.4 Films

0.3M enamels + silver paste

0.1 encapsulation raw materials

Full components range managed by 3 parties

No clear safety stock rules

No clear statement in between push & pull

lack of correct tooling : too much spreadsheets - too much homemade excels

New EOL/EOP procedure in place

Workshop Problem/solution:

1 - Customer demand: forecast (MTP01, , edi, ), short lead time (1week demand is fix but after 5 weeks it can changes),

2- BOM explosion (20M of component)

3- Stocks and needs

4- All excel files everywhere

More and more supplier are asking to be connected to them through EDI

Biggest issue: More reliable customer demand!!!!! : Then BOM Explosion: There is a lack of comunication. Some changes are done but the information is not shared

Tout est fait sur excel, bcp de check in l'un sur l'autre pour vérifier que les données sont bien mis sur excel !!!! ayayyae

Workshop (other group) :

Forecast (6 months) ⇒ BOM

Alerts and color codes. statitc rules. take a lot of time to go through every line. For the red lights, redo the replenishments.

Issue with forecasts is that it can change a lot from one month to the other. 1 month committed for forecast of customers.

Using a lot of different tables for BOM tables. (3 different ways - giving 3 diffferent results)

After BOM. 3rd step. Excel with :

• Production plan (only excel files)

• Supplier lead time

Safety operational stocks for 30 days (to have all components for production). Delay of 1 week.

Need to ask the planners how much is going to be the next production

Huge problem with real consumption made by 9 different planners on 9 lines.

Poland : Sandra Kwiecinska

Safety stocks ⇒ who made the decision? ⇒ no idea. safety stocks crystal ball. Out-of-stocks sometimes ? ⇒ sometimes, SC director is asking for more stocks. —> Smallest quantity necessary for the production

IT

No graphs and no projections of stocks.

Solutions :

1- Have correct data in the system.

2- Firm orders for the forecast

3- RFID for the stock viz