Sirius Logistics worked with a major automotive manufacturer to determine the physical logistics requirements for a new model. This work applied to two areas of the factory, Body in White (where the vehicle body is manufactured prior to painting) and Vehicle Assembly.

When a new model is being prepared information is continually changing and it is difficult to put a stake in the ground. Logistics need to respond constantly, generating information about the overall project and each part specifically. 

Sirius Logistics supported the manufacturer by creating a tool that interprets part level data overlaid with process assumptions and generates space and flow information for logistics including storage, sequencing operations and linefeed requirements. This relatively simple spreadsheet tool provides the detail to underpin high-level space requirements. It can be re-run with changes in assumptions, new part level information and new process requirements as often as is required.

The inputs are parts data and process assumptions. The outputs are high level space summaries and detailed information by storage type and manufacturing process relating to racking requirements, pallet stock holding and material flow.

This information was then used to create a detailed ‘first off’ layout to be developed as the project progresses and the data and assumptions mature. This layout was overlaid with all the major material flows and opportunities and risks identified early in the project lifecycle.

 

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Case Studies

Material Flow Analysis - for a Vehicle Manufacturer     

New Vehicle Physical Logistics   

Logistics Process Design - for a Component Manufacturer   

Papers

Car Distribution - A Rethink   

Logistics Supplier Management - A Holistic Approach