Manuel SchneiderSeptember 2010Bild 1 The growing from a local to global player Finding a verified delivery date within a global acting company Dipl. Wirt.-Ing

Manuel Schneider September 2010 Bild 2

• presentation of the company

• Development

• inhouse processes

• cross–plant processes = Direct Shipment

• finding a delivery date = CTP Multisite

• functions of PSI Penta


over 1000 employees world-wide

about 580 in Germany

represented in over 50 countries

20 own sales companies

6 production plants

headquarters in Ingelfingen, Germany

founded 1964 by Fritz Müller

high social commitment

R+D portion approx. 5%

proportion of apprentices approx. 9%

GEMÜ – an international successful family owned enterprise, based in the Hohenlohe area, the strongest region of Baden-Württemberg, South Germany

Facts and figures

Turnover in Thousand €

Employees

Investments


GEMÜ develops and produces state-of-the-art process, control and regulating valves, valve instrumentation, measurement and control systems

Pharmaceutical and biotechnology industries, cosmetics

Beverage and foodstuff industries

Microelectronics and semiconductor industries

Chemical industry and environmental systems

Machine, apparatus and plant engineering

Water treatment and supply

Nearly all sectors of the processing industry

Dedicated to the world of valves

Our products control and regulate liquids, gases and steam in:


Customized solutions

Modular design system

Large range of products, over 300,000 active product versions

System solutions

One-Stop Shopping

Global presence

High manufacturing capacities and availability

Reliable manufacturing quality

Designed in Germany,innovative research and development

System solutions from a single source

Your first choice in valve technology.


upstream (production to stock)

downstream(customer order processing)

receiving dpt.

manufacturing dpt. Assembly

shipping dpt.

finished goodsraw material

customer order processing

main warehouse

GEMÜ-logistics

Single

partsFinished

goods

module


Logistics in a few words…

1998 2010

item masters 80.000 350.000Items in stock 7.500 16.000Bom lists 35.000 209.000 customer transaction 110.000 420.000 delivery notices 45.000 210.000production orders 74.000 (2001) 150.000 purchasing orders 49.000


Feedback control in materials management

Solution statement:

Use the philosophy of a cascading control system to reduce the manual processes.

Realization:

ERP system just informs and does not

react.



assembly production purchasing

DPA

SRM

DPA / RAL




DPA

DPA / RAL

SRM




DPA

DPA / RAL

SRM




DPA

DPA / RAL

SRM


Multisite + Direct Shipment

Realization:

The development to a Global Player demands cross–plant logistics business processes.

Solution statement:

Use the philosphy of multisite erp installation to define consistent processes across the

sites


Gemü


Gemü


enter an order order, amount, date requested

enter customer transaction

scheduling, availability, load

order confirmation, amount,

confirmed date

order, amount, date requested


confirmed date

confirming order and new delivery date

dispachdelivery notice

invoice

delivery noticereceiving

invoicechecking

GEMÜ France GEMÜ Germany

basic cross plant order process



GemüGemü



order amount, date requested

Enter Customer Transaction


confirmed date

order, amount, date requested

order confirmation,amount,

confirmed date

confirming order and new delivery date

delivery notice

invoice

delivery notice

invoicechecking


GEMÜ France GEMÜ Germany

enter an order

scheduling, availability, load

dispach

receiving

basic cross plant order process


Gemü



GemüGemü

48h

24h



GEMÜ logistics center

Work order incl. all delivery dates (Multisite Standard)

customer

invoice

consignmentbooking the goodspackingresponsible for type signs, documents, delivery notices

order

invoice

Gemu sales company

dispach


store

store of finished goodscomponent store

goods

RHB

submitting an offerconsulting service recording an orderinvoice


Gemü



Montage Fertigung Einkauf

DLZ

NLFC CTP

DPA

SRM

DLZ W u n s c h t e rm inE rz e u g n is

h e u t e

D L Z B G A r ti k e l A

K o m p o n e n t e n a r t ik e l m i t f r e ie n L a g e rb e s t ä n d e n

b z w . f r e ie n Z u g ä n g e n



s c h e m a t is c h eA r ti k e l s t ru k tu r CTP

0

0

30

95

Woche3

50

0

20

65

Woche4

000GrobgeplanteBestellungen

0200Bestellungen imSystem

151510PrognostizierterVerbrauch

Bestellpunkt= 70

10590100PrognostizierterBestand

Ist-Bestand=100

Woche5

Woche2

AktuelleWoche

Teil 4711

0

0

30

95

Woche3

50

0

20

65

Woche4




Bestellpunkt= 70


Ist-Bestand=100

Woche5

Woche2

AktuelleWoche

Teil 4711

NLFC

Gemü



FRANCE sales

Implementation PENTA : 2005

Stock value: 1,5 M€

In-house manufacturing (assembly) : 50%


further process in sales departement

phone call of customer=> to query an offer

Stock in France!

phone call to storekeeper…

Stock in France!

phone call to storekeeper…

enter the offer scheduling

submitting a quick and satisfying offer to customersubmitting a quick and satisfying offer to customer


FRANCE sales

New situation

Inventory reduction : 2007

Stock value : 0, 3 M€

Direct delivery : 80%


process in sales departement

No stock in France!

no phonecall to storekeeper possible

No stock in France!

no phonecall to storekeeper possible

scheduling

customer gets offer with rough and imprecise scheduling

customer gets offer with rough and imprecise scheduling

phone call of customer=> to query an offer

enter the offer


Consequences

- calculation of offers and orders is faster - better delivery times because of direct delivery- structural optimization

BUT….

Less reliability of delivery dates in offers.This meant that:

• sales gave longer delivery times • bad image (loss of orders?)

There has to be a possibility finding the correct dates!


CTP Multisite

Realization

Direct Shipment demands company – wide information about capacities and stock and their

availability.

Solution statement:

Use of CTP Musi


Summary of requirements of CTP MUSI

CTP MUSIfor offers and orders:

1. fast calculation of delivery times2. based on free available inventory3. based on free available capacity 4. rough planned reservation of inventory 5. consideration of P2P or rather P2C transport times6. Totally integrated in erp system

CTP Multisite


Request

CTP 1

Calculated date not OK

Calculated date OK

Delete customer transaction in GEMÜ DE

Requirements planningCancel customer

transaction

Customer transaction

Standard handlingCheckingOrder

confirmation

GEMÜ GB GEMÜ DECustomer

CTP Multisite


CTP Multisite

Implementation in erp system

NUI Network User Interface

Automation Server

PSIpentaApplication Server

database

context plant1

Remote BOB Server

OCI

DCOM

TCP/IP

Client

Server

context plant2

plant 1 plant 2


Request

CTP 1


Calculated date OK



transaction



confirmation


CTP Multisite

1


CTP Multisite: calculation of delivery times

1. Request is transmittet automatically to supplying plant

2. automate calculation of dates by CTP1, Free Available stock ? If Yes: callculated date = wishdate customer

allocate stock

3. calculated date + transport time are send to Customer Transaction in France




2. automate calculation of dates by CTP1, Free Available stock ? If Yes callculated date = wishdate If No: checking of components

Free available stock on component level ?

If Yes: allocate stock and calculated date = Today + standard trough put time

3. calculated date + transport time are send to Customer Transaction in France



2. automate calculation of dates by CTP1, Free Available stock = No If Yes callculated date = wishdate If No checking of component Free vailable stock on component level ?

If Yes: allocate stock and calculated date = Today + standard trough put time If No: calculated date = Today + trough put time + lead time

(and so on)

3. calculated date + transportation time are send to Customer Transaction in France



Required Date

today

Start PSIPENTA0

10

23

-4

20

13.11.10

09.11.10

17.12.10


Example :

g1no goods in stock

no free receipt


Required Date

today0

10

23

-2

20

Example :

g1no goods in stock

no free receipt

13.11.10

23.12.10



Montage Fertigung Einkauf

DLZ

NLFC CTP

DPA

SRM

DLZ W u n s c h t e rm inE rz e u g n is

h e u t e

D L Z B G A r ti k e l A





s c h e m a t is c h eA r ti k e l s t ru k tu r CTP

0

0

30

95

Woche3

50

0

20

65

Woche4




Bestellpunkt= 70


Ist-Bestand=100

Woche5

Woche2

AktuelleWoche

Teil 4711

0

0

30

95

Woche3

50

0

20

65

Woche4




Bestellpunkt= 70


Ist-Bestand=100

Woche5

Woche2

AktuelleWoche

Teil 4711

NLFC

Gemü

Triology

Request

CTP 1


Calculated date OK



transaction



confirmation


Documents

Manuel SchneiderSeptember 2010Bild 1 The growing from a local to global player Finding a verified delivery date within a global acting company Dipl. Wirt.-Ing