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The supply chain for an OEM can be several levels deep. This is true of industries from cars to lawn mowers, from motorcycles to appliances.
The following is typical supply chain for an auto OEM for just some of the assemblies and components.
Multiple lines can exist at each level, for example:
- Trim / assembly line: 1
- Engine assembly line: 1
- Mission assembly lines: 2
- Machining lines: 2 for mission case, 2 for torque converter case
- Die casting lines: 2
- Paint shop: 1
- Weld lines: 2
- Stamping: 4 presses
- Blanking: 2 blanking machines
Vendor scheduling requires a multi-tiered approach.
- Demand at each level is derived from the higher level
- Multiple demand sources may exist:
- For example, stamping receives demand from weld line and spare / service parts.
- Production capacities may not be balanced:
- For example, one power train plant supplies multiple vehicle assembly plants.
- Inventory buffer management is critical at each level.
Scheduling a vendor plant, whether in-house or outsourced, is a very complex problem requiring balancing several and often competing factors.
- Derive demand / requirements from multiple sources including main / feeder line requirements, exceptional requirements such as special builds, service parts, and any other demand sources.
- Ability to schedule large production volumes with product variety.
- Balance schedule across multiple lines while optimizing both capacity and line capability.
- Ability to set process times based on product feature or part to line combinations.
- Ability to adjust requirement due dates based on shipping lead time for multiple destinations which allows parts to be scheduled in such a way inventory can be minimized.
- Ability to minimize and smooth overtime usage or idleness across multiple lines based on optimal conditions and/or user specified shift preferences.
- Capability to manage multiple constraint types that consider:
- Inventory targets
- Due dates
- Part change over times
- Capacities
- Ramp up / build out plans
- Packing block sizes for pallets / trays / hangars etc.
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