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GRAMMER Milestones
GRAMMERs success started more than 100 years before when Willibald
Grammer founded a saddlery in Amberg. Since then GRAMMER developed itself
from a local manufacturer of seat cushions to a global automotive supplier for the
car and commercial vehicle industry.
1880
1954
1970
1982
1985
1990
1996
IPO of GRAMMER AG
2004
2005
2008
2011
2012
2013
Functional details
Functional details
OEM
Components 1
Assembly line
Challenges today
JIS plant
Components 2
Low-Runner
IC plant
Missing transparency
Supplier A
Supplier B
Supplier A
Ongoing coordination of
involved persons is required
A stable planning and according processes are a prerequisite for levelling in production,
replenishment and procurement processes
Functional details
KANBAN
calculation
Alignment
Supplier park
Production plant
Components 1
Assembly line 1
push
pull
Components 2
Low Runner
Demanddriven
Heijunka
JIS plant
JIS
Assembly line 2
push
supermarket
push
JIS plant
JIS
Goods receipt
Pull
IC plant
IC plant
OEM
External
supplier
Calculation of
safety stock
OEM
Functional details
Segmentation
EPEI
calculation
Define
schedule
Simulate
schedule
Segmentation:
Identification of material groups with
individual planning processes and
requirements (e.g. differentiation of high
runners and low runners)
EPEI calculation:
Determination of the minimal lot size
Define schedule:
Specification of time intervals for the predefinition of the production sequence
Simulate schedule:
Align schedule and actual production plan
Calculate
safety stock
Alignment
Short-term
planning
Levelling
Pull
Alignment:
Levelling:
Pull:
Replenishment of components
according to the real consumption
Segmentation
EPEI
calculation
Define
schedule
Simulate
schedule
Calculate
safety stock
Alignment
Short-term
planning
Levelling
Pull
system integrated leveling keeps demand fluctuations from shop floor to enable a more
efficient production process
there are high- and low runners, and production needs to be mixed
different kinds of leveling have to be supported: Push, Push-Pull and Pull-Leveling
Heijunka needs a good visualization
SAP and Lean is not a contradiction, its the combination of the benefits of PUSH & PULL:
SAP covers both approaches, PUSH and PULL
Initial Situation:
materials
requirements
fluctuate over
time
but efficient
manufacturing
needs steady
quantities
Solution:
demand fluctuations are covered by a buffer; buffer size is calculated according to fluctuations size
and service level required
goods are produced in leveled, steady quantities, filling the buffer
all calculations are performed by the system; manual interaction needed only in case of exceptions
many other leveling variants possible (e.g. Pull / Push-Pull), depending on requirements
production orders with e.g. leveled quantities can be displayed, sequenced etc.
rhythm wheel / production schedule functionality can be used
mixed sequence of high / low runners
direct access to relevant data
conflicts (e.g. missing components, tools, etc.) can be visualized
solution combines the features of a Heijunka-board, combined with the comfort of a planning cockpit
Capacity
view
Stock level
view
Visualization
of order
sequence
flexible &
adjustable
menus and
buttons
Sequencing
according to
different
criteria (e.g.
setup matrix)
Alle relevant data
available (> 900
columns in ALVGrid)
Functional details
Segmentation
EPEI
calculation
Define
schedule
Simulate
schedule
Calculate
safety stock
Short-term
planning
Alignment
Levelling
Segmentation
Value/benefit contribution
Asset utilisation
Disturbances
Cycle time
Safety stock
Stock to cover increasing
demand
With consideration of
Operating times
Maintenance
EPEI
OEE-Influence, pre-setup
Reserve capacities
Setup changes
Stock areas, box sizes and
box availabilities
Operating times
EPEI classes
Pull
Segmentation
EPEI
calculation
Define
schedule
Simulate
schedule
Calculate
safety stock
Short-term
planning
Alignment
Levelling
EPEI calculation
Overall shift duration
Production duration
Stop time
Shift decoupling
Setup time
Based on demand
forecast and output
rate for the whole
product portfolio per
shift (incl. Scrap)
Based on statistical
reports of shift
protocols (average
values)
Establishing of a
shift decoupling
covering 80% of
occurred stop times
Usage of the
residual available
time per shift for
setup
Pull
Segmentation
EPEI
calculation
Define
schedule
EPEI calculation
Simulate
schedule
Calculate
safety stock
Alignment
Short-term
planning
Levelling
Pull
Segmentation
EPEI
calculation
Define
schedule
Simulate
schedule
Calculate
safety stock
Alignment
Short-term
planning
Levelling
Pull
Replenishment, consumption
Stock variation
parameter settings
Disturbances, buffer
Operating time
Requirements planning:
Alignment
Master data maintenance for alignment/levelling
Segmentation
EPEI
calculation
Alignment
Production capacity is
adapted to alignment
Customer specific
implementation is
possible
Daily production
quantities basis for
sequencing
Planning of low
runners by date
Define
schedule
Simulate
schedule
Calculate
safety stock
Alignment
Short-term
planning
Levelling
Pull
Segmentation
EPEI
calculation
Define
schedule
Simulate
schedule
Calculate
safety stock
Alignment
Pull
Consumption plant
Manufacturing:
Replenishment:
Short-term
planning
Levelling
Pull
Segmentation
EPEI
calculation
Define
schedule
Simulate
schedule
Calculate
safety stock
Alignment
Short-term
planning
Levelling
Pull
EPEI
calculation
Define
schedule
Features:
Simulate
schedule
Calculate
safety stock
Consumer
plant
Planned delivery time
Source
Alignment
Levelling
Pull
Stock level planning is optimised: buffer stock is reduced Stock areas get smaller costs
of stock keeping are reduced
Segmentation
In SAP ERP
EPEI
calculation
Define
schedule
Simulate
schedule
Calculate
safety stock
Alignment
Levelling
Pull
Supplier park
Production 1
Pull
Assembly line 1
Define/simulate
schedule
pull
JIS plant
JIS
OEM
Assembly line 2
Production 2
Low -Runner
push
Supermarket
push
Goods receipt
Pull
External
supplier
JIS plant
JIS
OEM
Calculate
safety stock
Production plant
Segmentation
IC plant
push
Alignment
Calculate
safety stock
IC plant
Levelling
EPEI
calculation
Functional details
IT oriented
SAP SCM is too complex (heuristic with characteristic based or model mix planning)
Standard capacity levelling in SAP ERP (graphical planning table) has gap of transparency
Infinite planning is too less ( finite planning with Heijunka board is required)