物流英语课堂报告 H.C. Starck, Inc H.C.斯塔克公司案例
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2.3 Complex Process
Flowing through multiple process oreders before ending up as the final
4'' bar 1/4'' plate
1/8'' plate
0.015'' sheet
Tubing
Production order #1
7,838
28,394 44,151 23,731 46,591
9,296
15,981 11,383 16,287 9,792
0.62
2.24 3.48 1.87 3.67
0.12
0.45 0.70 0.37 0.73
2.03
3.48 2.48 3.55 2.13
0.41
0.70 0.50 0.71 0.43
Gauge
Jan.
618 434 20 76 0 6 0 321 15 0 228
1201
Feb.
1079
Mar.
1215
Apr.
1188
May
1020
June
290 969 216
1035
July
1590
Aug.
849 376 143 418 408 17 246 176
Sept.
1017
SUM
Sheet bar (forged ingot) Roll Clean
Anneal
Finish (cut,weld,etc.)
Repeat 0≤n≤3 n 0 1 Final gauge(inches) 0.250~3.990 0.060~0.249
2
3
0.015~0.059
0.000~0.014
FIGURE 3-23 Basic production process
AVG
43,878
16,070
3.46
0.69
3.50
0.70
2 Reasons for Long Lead Time
2.6 Unsuitable Product Diversity
Four different alloys Over 600 unique part numbers FIGURE 3-31 Invoiced sales for alloy #1 FIGURE 3-32 Invoiced sales for alloy #2
Days of breakdown
Load factor of breakdown
Days of finish
Load factor of finish
Jan. Feb. Mar. Apr. May. June July
28,936 68,001 38,210 78,514 61,782 43,176 57,216
Logistics & Supply Chain Case Study
H.C. Starck, Inc
XXX
Contents
1 Introduction to H.C. Starck,Inc 2 Reasons for Long Lead Time 3 Measures to Shorten the Lead Time 4 Cost and Benefit
1224
60 1321 1236 432 4271 590 20 14 45
6.67 146.78 137.33 48.00 474.56 65.56 2.22 1.56 5.00
0 322 0 0 12 45
12 0 2 0
FIGURE 3-31 Invoiced sales for alloy #1
SWOT
Opportunity: •Gradually increasingdemand •Developing economy
2 Reasons for Long Lead Time
2.1 Too Much Waste in Manufacturing Process
'Fishtailing' and edge cracks→A trim loss of 20 percent Stop rolling and trim cracks→Extension of lead time
576 155 716 60 12 122 101 146 27 8 0 0 192 0 0 0 0
584 301
1263
832 211 167 243 827 275 486
617 41
1917
572 572 321 273 0 686 263
909 276 404 392 174 177 690
Problems of ERP System
• Standard costs • Ignoring real condition
2 Reasons for Long Lead Time
2.5 Low Operation Efficiency
A two-week cycle
Breakdown
Demand of Each Gauge
2500 2000 1500 1000 500 0
Sept.
0.002 0.005 0.01 0.015 0.02 0.025 0.03 0.04 0.06 0.102 0.125 0.15 0.375 0.5 0.75 0.8 1 1.125
Feb.
Mar.
0.002 0.005 0.01 0.015 0.02 0.022 0.025 0.03 0.035 0.045 0.06 0.118 0.125 0.15 0.375
2.28 5.36 3.01 6.19 4.87 3.40 4.51
0.46 1.07 0.60 1.24 0.97 0.68 0.90
2.68 2.36 5.34 4.82 4.39 5.29 3.46
0.54 0.47 1.07 0.96 0.88 1.06 0.69
Aug.
Sept. Oct. Nov. Dec.
102 0 614 191
147 0 422 8
305 770 360 98
56 117 129 414 581 191 1690 187.78 FIGURE 3-31 Invoiced41 sales for alloy #1 33 32 0 0 353 0 0 0 0 0 90 0 0 114 8 0 0 0 0 455 0 57 880 12 20 0 0 0 17 35 0 147 558 0 0 0 0 8 0 375 598 0 0 0 0 0 0 0 0 441 0 0 0 0 0 483 0 0
June
July
Jan.
Apr.
May
Aug.
Gauge
Jan. 551 0 0 108 761 0 296 1638 0 214 0
0
Feb.
0
Mar.
0
Apr.
0
May
0
June 0 0 412
127
July
0
Aug. 0 0 0 343 27 0 528
Sept. 0
SUM 551 12 1098 3055 13028 1014
2 Reasons for Long Lead Time
2.4 Backward Fra Baidu bibliotekanagement
A new installed ERP system (SAP’s R/3) Production planning and sheduling be performed manually
Production order #2
Production order #3
FIGURE 3-30 Multiple process orders
2 Reasons for Long Lead Time
2.3 Complex Process
Repeated cycle of roll-clean-anneal
8866 5869 1935 6317 1930 1806 2902 2334
AVG
985.11 652.11 215.00 701.89 214.44 200.67 322.44 259.33
STDEV
372.06 206.36 164.19 601.53 145.11 343.72 224.14 214.05 188.67 13.31 196.20 399.04 124.07 370.40 184.74 6.67 3.97 15.00
1 Introduction to H.C. Starck,Inc
Tantalum reduction and Tantalum powder manufacturing operations in Japan, Thailand, and Germany Newtown, MA, location is the only plant with melting and mill capability. Headquarters is located in Germany.
1 Introduction to H.C. Starck,Inc
Strength: •Tantalum has a widely usage •Low cost and technology superiority •An ERP system •Different types of products Weakness: •High price of tantalum •ERP system is not connected with real information •A uncertain of the supply of material •A problem in process Threat: Chinese company might improve their technology to polish up the quality of tantalum wire, in order to enter into the Rolled products market.
AVG 61.22 1.33 122.00 339.44
1447.56
STDEV 183.67 2.65 189.74 475.18
2086.46
C.V 3 1.992 1.555 1.399 1.441 2.999 0.69 0.593 2.999 0.767 1.195 2.985 1.45 2.997 2.996
5 Conclusion
1 Introduction to H.C. Starck,Inc
Be founded in 1940
Purchased 50% of shares of the NRC company Entered into the metallurgical product market in 1980 More than 2007 employees Overnine hundred million euros sales amount
C.V
0.378 0.316 0.764 0.857 0.677 1.713 0.695 0.825 1.005 1.997 1.337 2.906 2.585 0.781 2.818 3.000 2.554 3.000
0.002 0.005 0.010 0.015 0.020 0.025 0.030 0.040 0.060 0.102 0.125 0.150 0.375 0.500 0.750 0.800 1.000 1.125
2.2 Inappropriate Inventory
A high level of tantalum inventory Scrap is often brought more than is needed Standard gauges is not enough
2 Reasons for Long Lead Time
1 7
Rolling
14
TABLE 3-10 Large Mill Production Report(1998)
TABLE 3-10 Large Mill Production Report(1998)
Month Breakdown
Finish 12,307 10,828 24,529 22,122 20,155 24,277 15,880
Tantalum-containing tin slags and mined ore are processed
and refined to the tantalum 'double salt' K2TaF7. Rolling down and advanced manufacturing
Flowing through multiple process oreders before ending up as the final
4'' bar 1/4'' plate
1/8'' plate
0.015'' sheet
Tubing
Production order #1
7,838
28,394 44,151 23,731 46,591
9,296
15,981 11,383 16,287 9,792
0.62
2.24 3.48 1.87 3.67
0.12
0.45 0.70 0.37 0.73
2.03
3.48 2.48 3.55 2.13
0.41
0.70 0.50 0.71 0.43
Gauge
Jan.
618 434 20 76 0 6 0 321 15 0 228
1201
Feb.
1079
Mar.
1215
Apr.
1188
May
1020
June
290 969 216
1035
July
1590
Aug.
849 376 143 418 408 17 246 176
Sept.
1017
SUM
Sheet bar (forged ingot) Roll Clean
Anneal
Finish (cut,weld,etc.)
Repeat 0≤n≤3 n 0 1 Final gauge(inches) 0.250~3.990 0.060~0.249
2
3
0.015~0.059
0.000~0.014
FIGURE 3-23 Basic production process
AVG
43,878
16,070
3.46
0.69
3.50
0.70
2 Reasons for Long Lead Time
2.6 Unsuitable Product Diversity
Four different alloys Over 600 unique part numbers FIGURE 3-31 Invoiced sales for alloy #1 FIGURE 3-32 Invoiced sales for alloy #2
Days of breakdown
Load factor of breakdown
Days of finish
Load factor of finish
Jan. Feb. Mar. Apr. May. June July
28,936 68,001 38,210 78,514 61,782 43,176 57,216
Logistics & Supply Chain Case Study
H.C. Starck, Inc
XXX
Contents
1 Introduction to H.C. Starck,Inc 2 Reasons for Long Lead Time 3 Measures to Shorten the Lead Time 4 Cost and Benefit
1224
60 1321 1236 432 4271 590 20 14 45
6.67 146.78 137.33 48.00 474.56 65.56 2.22 1.56 5.00
0 322 0 0 12 45
12 0 2 0
FIGURE 3-31 Invoiced sales for alloy #1
SWOT
Opportunity: •Gradually increasingdemand •Developing economy
2 Reasons for Long Lead Time
2.1 Too Much Waste in Manufacturing Process
'Fishtailing' and edge cracks→A trim loss of 20 percent Stop rolling and trim cracks→Extension of lead time
576 155 716 60 12 122 101 146 27 8 0 0 192 0 0 0 0
584 301
1263
832 211 167 243 827 275 486
617 41
1917
572 572 321 273 0 686 263
909 276 404 392 174 177 690
Problems of ERP System
• Standard costs • Ignoring real condition
2 Reasons for Long Lead Time
2.5 Low Operation Efficiency
A two-week cycle
Breakdown
Demand of Each Gauge
2500 2000 1500 1000 500 0
Sept.
0.002 0.005 0.01 0.015 0.02 0.025 0.03 0.04 0.06 0.102 0.125 0.15 0.375 0.5 0.75 0.8 1 1.125
Feb.
Mar.
0.002 0.005 0.01 0.015 0.02 0.022 0.025 0.03 0.035 0.045 0.06 0.118 0.125 0.15 0.375
2.28 5.36 3.01 6.19 4.87 3.40 4.51
0.46 1.07 0.60 1.24 0.97 0.68 0.90
2.68 2.36 5.34 4.82 4.39 5.29 3.46
0.54 0.47 1.07 0.96 0.88 1.06 0.69
Aug.
Sept. Oct. Nov. Dec.
102 0 614 191
147 0 422 8
305 770 360 98
56 117 129 414 581 191 1690 187.78 FIGURE 3-31 Invoiced41 sales for alloy #1 33 32 0 0 353 0 0 0 0 0 90 0 0 114 8 0 0 0 0 455 0 57 880 12 20 0 0 0 17 35 0 147 558 0 0 0 0 8 0 375 598 0 0 0 0 0 0 0 0 441 0 0 0 0 0 483 0 0
June
July
Jan.
Apr.
May
Aug.
Gauge
Jan. 551 0 0 108 761 0 296 1638 0 214 0
0
Feb.
0
Mar.
0
Apr.
0
May
0
June 0 0 412
127
July
0
Aug. 0 0 0 343 27 0 528
Sept. 0
SUM 551 12 1098 3055 13028 1014
2 Reasons for Long Lead Time
2.4 Backward Fra Baidu bibliotekanagement
A new installed ERP system (SAP’s R/3) Production planning and sheduling be performed manually
Production order #2
Production order #3
FIGURE 3-30 Multiple process orders
2 Reasons for Long Lead Time
2.3 Complex Process
Repeated cycle of roll-clean-anneal
8866 5869 1935 6317 1930 1806 2902 2334
AVG
985.11 652.11 215.00 701.89 214.44 200.67 322.44 259.33
STDEV
372.06 206.36 164.19 601.53 145.11 343.72 224.14 214.05 188.67 13.31 196.20 399.04 124.07 370.40 184.74 6.67 3.97 15.00
1 Introduction to H.C. Starck,Inc
Tantalum reduction and Tantalum powder manufacturing operations in Japan, Thailand, and Germany Newtown, MA, location is the only plant with melting and mill capability. Headquarters is located in Germany.
1 Introduction to H.C. Starck,Inc
Strength: •Tantalum has a widely usage •Low cost and technology superiority •An ERP system •Different types of products Weakness: •High price of tantalum •ERP system is not connected with real information •A uncertain of the supply of material •A problem in process Threat: Chinese company might improve their technology to polish up the quality of tantalum wire, in order to enter into the Rolled products market.
AVG 61.22 1.33 122.00 339.44
1447.56
STDEV 183.67 2.65 189.74 475.18
2086.46
C.V 3 1.992 1.555 1.399 1.441 2.999 0.69 0.593 2.999 0.767 1.195 2.985 1.45 2.997 2.996
5 Conclusion
1 Introduction to H.C. Starck,Inc
Be founded in 1940
Purchased 50% of shares of the NRC company Entered into the metallurgical product market in 1980 More than 2007 employees Overnine hundred million euros sales amount
C.V
0.378 0.316 0.764 0.857 0.677 1.713 0.695 0.825 1.005 1.997 1.337 2.906 2.585 0.781 2.818 3.000 2.554 3.000
0.002 0.005 0.010 0.015 0.020 0.025 0.030 0.040 0.060 0.102 0.125 0.150 0.375 0.500 0.750 0.800 1.000 1.125
2.2 Inappropriate Inventory
A high level of tantalum inventory Scrap is often brought more than is needed Standard gauges is not enough
2 Reasons for Long Lead Time
1 7
Rolling
14
TABLE 3-10 Large Mill Production Report(1998)
TABLE 3-10 Large Mill Production Report(1998)
Month Breakdown
Finish 12,307 10,828 24,529 22,122 20,155 24,277 15,880
Tantalum-containing tin slags and mined ore are processed
and refined to the tantalum 'double salt' K2TaF7. Rolling down and advanced manufacturing