MAN Nutzfahrzeuge AG Nuremburg: Engine Production

With the introduction of flexis Monitoring we are now able to detect part shortages earlier in the near term horizon. This in turn enables us to start the escalation process to avoid missing parts earlier and to prevent and reduce turbulences and costly retrofitting work in the assembly process.
Werner Mohri, MAN Truck & Bus AG

Components under control - More transparency on parts availability and manufacturability

MAN Truck & Bus AG manufactures diesel and gas engines in Nuremberg and supplies the complete internal manufacturing network of the commercial vehicle manufacturer. In addition, engines for special purpose vehicles, and marine and industrial engines are manufactured for external customers.

Overview all along the line

The number of required parts and different variants makes it difficult to keep track of the availability of parts. Transparency about the physical stock (on the line or in storage) is needed to ensure the smooth manufacturability of the scheduled sequence. The flexis solution now even includes those parts that are still in transit. In this way flexis contributes decisively to identify bottlenecks in time and to be able to take countermeasures selectively.

Manufacturability test in real-time

The flexis solution offers two main views. First, it informs the scheduler which jobs are affected by part shortages. Secondly, it indicates to the controller which parts cause bottlenecks. flexis also determines accurately the date and time of when parts will run out. Bringing all this data together provides a reliable basis in order to take appropriate measures in a timely fashion.

MAN Truck & Bus AG Nuremberg: Minimizing inventory despite of high diversity of components

Leaner production through safety stocks tailored to market demand Minimizing inventory is one of the key objectives for the pull-oriented material provisioning in MNPS, the production system of MAN Trucks AG in Nuremberg. MAN has set up so-called supermarkets, in order to provide the extremely high diversity components needed for truck assembly. With the help of a Control solution by flexis at MAN Trucks AG in Nuremberg the components are commissioned in order of the assembly sequence.

Supermarket Management

Currently, the supermarkets supply the assembly line with about 500 different part numbers. The goal is to continue to increase this number up to 1,500 part numbers. A particular challenge is the two-phased commissioning, which is carried out in the supermarket area. Here the so-called "ultra slow movers" are pre-picked and placed next to the regular supermarket areas. Analogous to the assembly operation, the commissioning is organized into parts families. For each order and each specific parts family, all exotic part numbers are commissioned into a sequence-container. With “LogiZug” these containers then automatically find their way to the assembly line. The sequence information is provided by flexis, the exact timing is the result of the pull event triggered by an empty sequence container. As reference the demand dates are used, which were calculated in the flexis application SMC (component availability).

The supermarket control system allows the visualization of the demand dates via an assembly summary. In addition each individual demand is tagged by means of a label printer. This way flexis provides time-and space-savings and supports the smooth running of lean production. For the case of missing parts the flexis solution includes a 30 day history, in which missing parts are highlighted in red. This allows the specific rework of individual orders, if necessary.

MAN Nutzfahrzeuge AG Salzgitter: Axle Assembly

With flexis Sequencing we have a flexible and reliable planning tool on hand that optimizes our high variant axle production significantly. The switch from push to pull principle was made possible due to the smooth implementation which is reflected in a significant reduction of inventories. flexis has fulfilled our expectations fully. The implementation meets exactly our plant specific requirements while providing the opportunity to make modifications or extensions anytime. In short - it has all the advantages of a modern planning system.
Thorsten Zimpel, MAN Truck & Bus AG

Complex and with many variants

The continuing trend towards large number of variants in the truck and bus industry increases demands on production planning. MAN Salzgitter is the bus production site of the commercial vehicle manufacturer. Heavy truck series are manufactured here as well. The axle assembly in Salzgitter provides various axle variants for internal and external customers. It is necessary to harmonize internal planning with the requirements of external customers.

Transparency causes adherence to delivery dates

flexis received the order to provide software which enables MAN to convert to schedule due date oriented planning. Before, planning was geared towards required quantities and the basis for production was large stock levels. The planning solution from flexis had to reduce the associated costs and make it easier for the planner to allocate orders to delivery dates. In addition, it is important to create transparency about the multitude of customers, axle variants and assembly times. This is especially important because customer delivery is partly done in just-in-time, and partly in lots, meaning number of pieces.

Sequencing in a steady and transparent manner

flexis provides the planner with an overview of all pending jobs. How many axles of which type must be made when? Are the necessary parts available to meet these demands? flexis provides the answers through concise visualization. The scheduling of jobs is in compliance with all production constraints. To shorten the storage time of manufactured orders, the sequence is aligned with trailer loads on the way to the customer. By batching different axle variants within the sequence, a smooth assembly process is achieved: The setup times for the machines on the assembly line were reduced by approximately 5% due to flexis.

MAN Diesel & Turbo SE: Production Planning

With the launch of flexis complex planning tasks can now be simulated and implemented in a very short period to time. High transparency and early detection of constraint violations pay off in form of precise expressiveness of possible delivery scenarios. Defined constraints, respectively technical capacities are stored in the master data. With this we can detect early on, whether the scheduling of engines with leveling of cylinder dependent parts for pre-assembly and mechanical manufacturing is feasible or not. Increased transparency in the order-to-delivery process provides the ability to identify possible scenarios and consequences on the production plan or the delivery dates.
Werner Göbel, MAN Diesel & Turbo SE

Optimization from sales planning to product delivery

MAN Diesel & Turbo SE in Augsburg relies on flexis Order Slotting when it comes to planning the production program. The particular challenge of producing large diesel engines and turbo engines is the time scope for the production steps. The inevitable planning horizon at MAN Diesel & Turbo extends three years into the future. The flexis solution visualizes demands and capacities along the whole process chain – from the foundry to engine delivery. The aims are to achieve utilization which is as even as possible by means of an equal distribution of orders and prevent bottle-necks in the long term. The transparency, the highest degree of individual configurability and the elevated simulation capability of the flexis solution guarantees reliable short- middle- and long term planning.

Safety through simulation

Besides the outstandingly free configurability, one of the main benefits of the flexis solution is that the current workload can be indicated and optimized according to the specific demands. The simulation abilities of the tool guarantee reliability of the planning results – despite of the considerable planning complexity, long planning periods and the high degree of variability. This doesn’t only allow the consideration and evaluation of a certain variant, but also creation and comparison of several different variants. With the help of Key Performance Indicators (KPI) the different scenarios can be validated. Thus the planner is able to ensure that he decides in favor of the best given alternative.