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Fábrica integrada: como encurtar os ciclos de projeto, planejamento e produção Painel Visão de Players Renato Leite (Siemens PLM), Daniel Bio (SAP) Mediador: Rogério Barra - PhD Berlin, Diretor e consultor em práticas PLM para a Prodcon/Ninecon
Citation preview
SAP - Fábrica integrada: como encurtar os ciclos
de Projeto, Planejamento e Produção
Daniel Bio
Abril 2014
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 2
Steering through the changing automotive environment
Customer demand highly configured cars but
remain very fickle
Uncertainty in global economic conditions
Compressed product development cycles
Underutilized production capacity
Escalating commodity and energy costs
Sustainable manufacturing and products
Increased competition and pricing pressure
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 3
Challenges
Fragmented R&D
departments are unable to
deliver desired innovations
quickly and in high quality
Global manufacturing
conspires to force high
inventory and logistics costs
Volatility in Global Supply
Networks challenges
efficacy of supply networks
Informed and demanding
customers along with
increasing competition puts
high pressure on profit
margins
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 4
High-impact strategies to drive top performance
High Impact Strategies
Enable Real-Time
Collaboration Across Extended
Product Design & Engineering
Teams
Eliminate Manufacturing Waste
& Synchronize Logistics With
Production
Create Visibility by Integrating
Multi-tier Global Supply
Networks
Deliver a Customer-Centric
Buying & Ownership
Experience
Objectives
Accelerate
Time to Market
Reduce Cost of
Goods Sold
Improve Cash
Flow
Drive Revenue
Growth
53% Faster time to market for new products
10% Lower manufacturing cost
29% Lower inventory days
35% Higher revenue per employee
Note: In comparison to average performers; Source: SAP Performance Benchmarking; all benchmarks are specific to automotive industry
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 5
Unmatched SAP expertise and traction
Manufacturing Volkswagen
General Motors
BMW
Deere
Hyundai/Kia
Nissan
Daimler
Goodyear
Johnson Controls
Faurecia
Bosch
Continental
Brose
TRW …
Sales & Service Volkswagen
General Motors
BMW
Deere
Daimler
Dong Fong
Inchcape
Proton Motors
Colmobil
GrupoQ
Al Mansout
Harley Davidson
Barlo World
Leug …
28of the top automotive manufacturers and suppliers
Multi-industry support on a
single platform
Deep automotive
industry-specific capabilities
Embedded preconfigured
best practices
Clear industry road map
3,000+ Automotive customers
worldwide
Source: SAP analysis of Forbes 2000 rankings (May 2013) and SAP customer database as of May 2013
A&D
23 global automotive dealer and OEM sales and service organizations
Auto
96%
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 6
SAP customers represent 79% of Global 500 companies.
SAP customers represent 85% of the top 100 most valued brands in the world.
Our customers manufacture more than 95,000 automobiles per day.
7 of the Forbes 50 Most Admired Companies in the World are SAP automotive
customers.
7 of the Forbes 100 Biggest Public Companies in the World are SAP automotive
customers.
Best-Run Customers
Best-Run Customers
7 © 2014 SAP AG or an SAP affiliate company. All rights reserved.
Our customers
manufacture more than
95,000 automobiles
per day.
8 © 2014 SAP AG or an SAP affiliate company. All rights reserved.
Our customers
produce more than
82% of the world’s
motorcycles.
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 9
Enable real-time collaboration across product
design & engineering teams
Enabling Solutions
Continuous Product and Service Innovation Identify opportunities to transform concepts into
products & optimize project management processes.
Integrated Product Development for Discrete
Industries Enable a consistent & accurate view of product data
for design collaboration & strategic sourcing.
Embedded Product Compliance Meet safety & environmental requirements through a
Total Quality Management approach.
Reduction in customer
orders past due 85%
“SAP solutions appealed to us because they are widely
used by companies with international operations. We now
have the scalability and flexibility we need to support our
customers and establish a foundation for growth.”
Brad Knauf, Senior Global Manager - Aftermarket Operations,
Dana Holding Corporation Source: SAP Performance Benchmarking
Best-Run Customers
High-Impact
Strategy
Business Impact1
14%
Shorter time to market for new products in
organizations that institute formal product life-
cycle management process
34%
Higher new product revenue (as % of total
revenue) for organizations that drive growth
with continuous innovation
1
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 10
SAP Solutions for R&D and Engineering Deliver Innovative Products with an Integrated Solution Approach
Service Make Design Imagine Plan
Manage big data, understand the past and predict the future
New user experience, embedded analytics, on mobile
Product data, structure and change management
Portfolio and project management
Embedded quality and compliance management
Concept Portfolio Ideation Design, Variants,
Recipes
Manufacturing Simulation Service Maintenance
Tool integration
platform CAD
Layout,
schema,
and code
CAE … Digital
Manufacturing ECAD,
Software
… …
Bill of
results Simulation
data
CAD
SAP PLM
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 11
New Authoring Tool Integration Strategy
Situation Today
Outdated UI
Partner specific implementations
No scale for growth
Limited functionality
New Tool Integration Strategy
New, harmonized UI
One integration platform for all kind of tools
Platform for growth
Enabler for Systems Engineering
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 12
SAP’s Authoring Tool Integration Strategy
SAP Engineering Control Center provides:
Consistent integration of authoring tools along the value chain
360 degree product view including mechanics, electronics, software, and simulation etc.
Embedded quality and sustainability management capabilities for the authoring tool interfaces
CATIA
V5
NX Creo Solid
Edge
Solid
works
Invent
or
Auto
CAD
Micro
station
Mechanical Design Electric
Electronic
Design
Software
Develop-
ment
Simulation …
SAP PLM/SAP ERP
SAP Engineering Control Center
CAD Service Layer
Imagine Design Plan Make Service
Visual Enterprise
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 13
Dana Holding Corporation, headquartered in Maumee, Ohio, is
a global supplier of engineering, manufacturing, distribution,
and service of drivetrain technologies, sealing systems, and
thermal management solutions.
Dana Holding Corporation chose the SAP ERP and the SAP Extended
warehouse applications to bring European aftermarket business in-house
after 10 years of outsourcing to improve service control and reduce costs.
Key Benefits
Replacement of disparate systems with a single global solution
A single integrated system to support the entire international
aftermarket distribution network
Closer customer relationships with improved satisfaction and sales
Greater visibility of operations to match supply and demand
Reduced costs and improved service levels
6 Months implemen-tation time at a new distribution center with no unplanned down time for customers
15% Improvement in customer order fill rate (from 80% to 95%)
85% Reduction in customer orders past due within six months
Dana Holding
Best-Run Customers
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 14
Eliminate manufacturing waste & synchronize
logistics with production
Enabling Solutions
Operational Procurement & Inbound Logistics
for Direct Material Standardize operations & processes for suppliers
and promote real time visibility into material demand.
Lean Manufacturing Eliminate waste of all kind, such as costs associated
with excess inventory, labor, and poor quality.
Make to Order Enable simulations & insight into material capacity &
labor constraints for highly variant products.
Outbound Logistics Promote tight process integration and real-time
visibility with customers & logistics service providers.
Order and inventory
accuracy 99%
Best-Run Customers
High-Impact
Strategy
Business Impact1
23%
Higher capacity utilization
in automotive companies when processes are
controlled by pull-based production schedules
rather than traditional shop orders
10%
Lower manufacturing cost (% of total revenue) for organizations where execution systems and the shop floor are integrated with enterprise applications
Source: SAP Performance Benchmarking 1
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 15
Part of the Paris-based Valeo Group, Valeo Service Benelux
B.V. supplies original equipment spare parts to automakers
and replacement parts to the independent aftermarket.
Valeo is aware that to maintain its strong market position, it needs to
constantly improve customer service and operational efficiency. Very
satisfied with its existing SAP ERP application, Valeo decided to
implement SAP warehouse management functionality. Having the
entire order-to-delivery process on a single platform would provide
the necessary degree of control and traceability.
Key Benefits
Improved stock and replenishment accuracy
Increased fill rate and eliminated second warehouse despite
25% increase in SKUs
Improved order and delivery traceability and improved customer
satisfaction
Paper-based picking replaced by mobile terminals with increased
accuracy and efficiency
99% Order and inventory accuracy
15% Improvement in fill rate
8% Fewer days in inventory
Order to delivery reduced from next day to 4–5 hours
Valeo
Best-Run Customers
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 16
Create visibility by integrating multi-tier global
supply networks
Enabling Solutions
Service Parts Management Integrate customer order processing with parts
sourcing, availability determination & claim handling.
Transportation Management Optimize fulfillment and spend by collaborating with
carriers across the entire order lifecycle.
Supply Chain Execution Integrate global logistics and fulfillment processes
across enterprise with real-time alerts & reporting.
Reduction in total
overhead cost 5%
“Reducing overhead costs by 5%, while increasing the
impact our contact centers have on customers, has been
a huge win for us.”
Bob White, Senior Vice President, Client and Fleet Services, ARI
Best-Run Customers
High-Impact
Strategy
Business Impact1
11%
Lower transportation spend (% of revenue) for
organizations that collaborate with contractors
& suppliers to get visibility into supply situation
7%
Higher forecast accuracy for organizations
that collaborate with external business partners
(contract manufacturer, suppliers, and so on)
Source: SAP Performance Benchmarking 1
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 17
Deliver a customer-centric buying & ownership
experience
Enabling Solutions
Dealer Business Management Streamline business operations & leverage real-time
data to drive enhanced sales & service processes.
Vehicle Sales Management Deliver full visibility throughout the entire vehicle
distribution chain by synchronizing supply & demand.
Customer Service, Support, and Warranty
Management Streamline & automate contract management,
resource allocation, and warranty / claim processes.
Multichannel Marketing Management Leverage consumer behavior & segmentation to
target cross-channel marketing activities.
Accuracy of sales quotation and dealer discount spend 100%
Best-Run Customers
High-Impact
Strategy
Business Impact1
14%
Higher customer satisfaction for top 25% of
organizations compared to average
organizations
15%
Lower inventory-carrying cost for
organizations that align supply to demand
Source: SAP Performance Benchmarking 1
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 18
As the country’s leading lift-truck supplier, Toyota Material
Handling U.S.A. Inc. (TMHU) supports independent dealers
nationwide.
TMHU chose SAP software including the SAP Customer Relationship
Management application to improve sales visibility and accuracy of
dealer sales quotations. TMHU also gained efficiency in order processing
and the management of its dealer discounts.
Key Benefits
Increased win rates with integrated lead management, marketing,
and analytics
Improved sales team productivity
Improved accuracy of sales quotations
Better visibility into sales pipelines and end-user pricing
Significant savings due to eliminating variance in dealer discounts
15% Improvement in market awareness
85% Reduction in order confirmation times
100% Accuracy of sales quotation and dealer discount spend
TOYOTA
Best-Run Customers
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 19
Al-Mansour Automotive Company is one of Egypt’s largest
importers, distributors, and retailers of motor vehicles, and
is the sole distributor of General Motors products.
The firm has a total market share of 27.7% and wanted to increase that
penetration via initiatives to generate more sales and improve service.
That’s why it turned to SAP Business Suite software and solutions from
the SAP for Automotive solution portfolio.
Key Benefits
Enabled growth plans without commensurate increase in headcount
Maintained highest operational key performance indicators of any
regional GM distributor
Enhanced Inventory control
Improved customer satisfaction
Shortened distribution delivery times
Improved customer satisfaction with reduced delivery times
Remarkable productivity gains
Streamlined processes and workflow
Al-Mansour Automotive
Best-Run Customers
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 20
PSA Peugeot Citroën is Europe’s second-largest automaker
and number seven globally, producing 3.2 million cars in 2009.
PSA Peugeot Citroën wanted to improve productivity in its 28 manu-
facturing facilities worldwide, 4 technical centers, and 1 tertiary site.
PSA replaced its legacy plant maintenance applications with the
SAP Enterprise Asset Management solution and developed standard
business processes based on best practices. In the next few years, the
solution will pay back PSA’s investment through heightened efficiency
and a better spare-parts list.
Key Benefits
Achieved productivity and organizational improvement throughout
the plants
Reduced spare parts inventory
Eliminated data reentry
Achieved productivity and quality targets
Improved preventative maintenance
Increase equipment availability
Production feedback loop to engineering
PSA Peugeot Citroën
Best-Run Customers
© 2014 SAP AG or an SAP affiliate company. All rights reserved. 21
SAP co-innovates with leading automotive companies using the global Automotive
Executive Advisory Council to drive priorities. Its member companies spur
co-innovations and enhancements across the entire automotive value chain.
Customer Co-Innovation
Automotive Executive Advisory Council
The Automotive Executive Advisory Council enables C-level executives to discuss and guide new
business innovations, technologies, and best practices to support best-run companies.
Co-Innovation Partners
Co-innovation workgroups of the Automotive Executive Advisory Council focus on in-memory
computing, mobile solutions, and dealer business management in addition to engineering,
manufacturing, and sales and service topics.
45% Of companies are regular
members of the Automotive
Executive Advisory Council
Best-Run Customers
© 2014 SAP AG or an SAP affiliate company. All rights reserved.
Obrigado
Daniel Bio
Ger Desenv Negócios
SAP Brazil
55 11 5503 2490
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