Volkswagen India Private Limited

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Volkswagen India Private Limited
Volkswagen Logistics, Sven Bockes
Logistics Management conference on 13.12.2013, Pune.
Returnable Container Management – LISON
Agenda
1. Introduction of logistics VW Pune
2. Facts and figures about the logistics at Volkswagen Pune
3. Requirement to implement a Returnable Container
management ( LISON )
4. Idea to install a standard solution at Volkswagen Group
5. Process flow of the standard solution
6. Milestones and achievements using a Container
management
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
Page 1/12
Organization structure of Logistics
Director Logistics
Carsten Goransch
Admin Assistant
Pallavi Shahasane
Technical Assistant
Senthil Kumar
Logistics Planning
(HoD)
Mr. Sven Bockes*
Logistics Disposition
(HoD)
Mr. Sven Bockes
Operative Logistics
(HoD)
Mr. Ulf Mohme
Program Planning
(HoD)
Mr. Carsten Steinicke
Preseries Logistics
(HoD)
Mr. Roberto Klein
PCB Malaysia
(HoD)
Mr. Ralf Seitz
Project Planning
G. Suresh
SAP/CKD/Custom
Andreas Lehmann
Logistics Plant control
Devendra Karpe
Program control
Rajesh Kulkarni
New Projects
Devendra Maral
Order Mgmt. &
Disposition
Ravi Kumar
Packaging Planning
Charusen Dave
Local Disposition
Ragunathan Kaliraj
Technical Office
Prakash Patil
Production control
S. Dongargaonkar
TAED
Mayur Sonawane
LSP Operations
Rohit Chaudhri
Cross function Team
Harshal Mehta
Vehicle Distribution
Rahul Kekan
Tech Info BOM
Sandeep Hebbar
Packaging Planning
Sumeet Kamble
Process Inbound
Mukund Korlahalli
Just in Time
Imran Shaikh
Claims / Debits
Randal Pereira
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Readiness
Niranjan Patil
Date: 28/11/2013
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Suppliers Information
 140 Suppliers
 10 Countries
Sources
 CKD
– 1.840 parts
 Direct Import
–
88 parts
 India (Local) – 1.468 parts
 JIT / Kanban – 732 parts
Location wise
Supply Base Location
11%
10%
India
 India
79%
 China
11%
 Rest of the world
Volkswagen India Pvt. Ltd. / Sven Bockes /
China
79%
10%
Logistics
Date: 28/11/2013
Rest of the world
Page 3/12
Overseas Supply Base
Germany
Korea
Czech Rep
China
Japan
Spain
Mexico
India
Singapore
Brazil
South
Africa
10 countries
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
Page 4/12
VW Supplier Base in India
Delhi
Uttar
Pradesh
Gujarat
Maharashtra
91 Local
9 Kanban
7 JIT Suppliers
Karnataka
Chennai
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
Page 5/12
Scope since 2011: Returnable Packaging concept VW
India
Concept
GLT
KLT
Total
%
Returnable
606
617
1223
One way
75
134
209
15%
Total
681
751
1432
100%
85% !!
Problem: How to manage a supply chain with returnable Container ?
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
Page 6/12
Solution through a Returnable Container Management
System
Idea: Using a standardized VW Group Returnable Container management system.
- LISON stands for Ladungsträger-Management und Informations-System Online.
LISON Container Processes are working within International Networks.
Challenge INDIA:
Region
Production Facilities
Suppliers
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
• Regional clusters of OEM and
suppliers
• Very long transportation routes
• Various different containers,
processes and infrastructure
Date: 28/11/2013
Page 7/12
The Container system and process flow
Ordering of containers,
based on part schedule
RCM Team
Ordering processing and
generating of tasks
Customers
( 91 Suppliers )
Source
Empties transportation to
the receivers
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
(VW Pune)
Page 8/12
Milestones to implement the RCM LISON
Phase 1: The base for the system implementation working with container master data.
This was realized in CW 31 / 2013.
Overall 1160 packaging instructions were filled into the system LISON.
Phase 2: In CW 36 / 2013 the module for shipments of container was released.
In total 330 container accounts were opened.
Phase 3: The Suppliers were enabled to view their account. Go Live was in CW 36 / 2013
Therefore 59 Suppliers were trained by Volkswagen.
Phase 4: A new base for the system filling was required.
For that reason the inventory of empty goods was
done in CW 43 / 2013.
Also this was sucessful; 133.361 Container were counted.
Participation: out of 91 suppliers 73 were taking part.
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
Page 9/12
Benefits using a Container management
(LISON)
Account control
Number of Containers
Total value
– 133.361
– 6 Mio. Euro
Dedicated standardized system
Stock management
330 Container accounts were opened and booking started.
Online stock available and Ordering process established.
Repackaging costs
Order fulfilling system ensures no shortage of Containers leading to
reduced repackaging cost.
Transparency of data
Packaging planning data and order status are available online.
Transport cost ( Sink and source – Planned for Future )
With more sources, Sink and source principle can be implemented.
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
Page 10/12
Benefit in optimizing the transport process
Carrier optimised empties distribution saves freight costs - example
Wolfsburg
Navarra
Auto
Europa

Group
Plants
Suppliers
Material Transport
Empties Transport
Out of 324.000 possible
transport routes, the optimal
ones can be selected
Average transportation distance savings: Production Facility  Supplier = 173km
reduction by approx. 38%
Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
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Volkswagen India Pvt. Ltd. / Sven Bockes / Logistics
Date: 28/11/2013
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