harley davidson - オルタナティブ・ブログ davidson - walking guide.pdfharley davidson...
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![Page 1: Harley Davidson - オルタナティブ・ブログ Davidson - Walking Guide.pdfHARLEY DAVIDSON MANUFACTURING PROCESS • Stamps VIN to the frame • Start of the use of carts to transport](https://reader033.vdocument.in/reader033/viewer/2022041911/5e6799baf080382fe46930ba/html5/thumbnails/1.jpg)
Harley DavidsonWalking SAP Tour Guide
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Welcome
3
WELCOME TO THE PLANT TOUR.
• What you will see. • About the SAP & Harley relationship. • Do we have any public press on what Harley has said
about SAP? • Use quotes . . . . . • Overview of the solutions Harley has deployed. . . .
TABLE OF CONTENTS
2
“Four wheels move the body. Two wheels move the soul.”“Four wheels move the body. Two wheels move the soul.”
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RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp & Tank
�I-/=� & Cafeteria
Paint StagingPress
(Fenders & Tanks)
Bend Frames. Weld Frames & Tanks
Lean Supplier Parts Market
5
Harley Davidson PlantA Day in The Life of an Order
4
IT Support
QA
Tank Leak Test CMMS
Maintenance
Recycling of Steel Scrap
<39<3>C�]��+8+1/��98G3->=
All orders
Fabrication
ASsmbly
Individual CustomerSupplier Stocking
New Parts
PLM – Variant �98F1
APO
Available
Version
Sales Order
Tells Suppliers Demand for Parts
Paint Schedule – 6 hours prior locked in for Plant
Sequence Carts for Assembly
Interface to SAP ME Control of AGC + Wrenches
+ Screw Guns (KLECO)
Based on mix and backlog of bike by type – Trike, Custom, Hard/
Soft Tail, etc.
Rolling 3 Month #
of Planned Orders
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76
Press (Fenders & Tanks)
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
HARLEY DAVIDSON MANUFACTURING PROCESS
• Steel rolls are cut and pressed • Cycle counts are captured for dyes and presses for
maintenance tracking purposes • Steel inventory is pulled based on schedule – not
schedule adherence
BUSINESS ISSUE
• Operated based on an assumed schedule – no re-al-time feedback
• Unsure of how much to produce • Steel inventory is pulled based on schedule not ac-
tual schedule adherence which caused excess inventory
SAP SOLUTION: SAP MANUFACTURING INTEGRA-TION AND INTELLIGENCE (SAP MII)
VALUE FOR HARLEY
• Real-time visibility into inventory and schedule at-tainment (SAP MII)
• · Integration to Plant Maintenance for mainte-nance of dyes and presses (SAP MII_
• · Track press quality based on benchmark using SPC/SQC – non-conformance, weld defects, and patterns to reduce scrap (SAP MII)
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HARLEY DAVIDSON MANUFACTURING PROCESS
• Frames and tanks arrive • Frames are bent and the tanks are welded onto the
bent frames
BUSINESS ISSUE
• Lack of vis3,363>C�0<97�=29:[G99<�>9�>2/�/8>/<:<3=/ • Inability to track non-conformance, weld defects,
or patterns • Excess inventory stemming from weld wire con-
sumed inventory, which was not captured in real-time
• Manually intensive process to move the right frames and tanks to the correct location based on schedule
SAP SOLUTION: SAP MII, RFID TAGS
VALUE FOR HARLEY
• Real-time visibility into weld wire inventory and schedule attainment (SAP MII)
• Integration to Plant Maintenance for maintenance (SAP MII)
• Track weld quality non-conformance, weld defects, and patterns to reduce scrap. In some weld cells, the non-conformance is captured automatically and in others through manual entry. (SAP MII)
• Post-weld, RFID tags are applied to the tanks and fenders for tracking (RFID tags)
Frames
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
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11
HEADELINE 1
Headline 2Headline 3Body copy. • Bullet • Bullet • Bullet
– Bullet 2
Paint Staging
HARLEY DAVIDSON MANUFACTURING PROCESS
• Paint colors are batched based on schedule • Prior to painting a tank leak test is performed
BUSINESS ISSUE
• Lack of real-time visibility into production and schedule – at the time a 3.5 week window
• Unable to prioritize based on orders – for example premium vs. regular
• Missing integration of CMMS for quality tracking which resulted in islands of information
SAP SOLUTION: SAP MII, CMMS
VALUE FOR HARLEY
• Integration to paint scheduling based on locking in schedule in 6 hour windows (SAP MII)
• Integration to CMMS for quality checks (SAP MII) • Integration into tank leak test results – providing
real-time visibility to schedule attainment (SAP MII)
• Checks on bends in bars/frame (CMMS) • Measures jig setup and accuracy in bend (CMMS) • Integration with CMMS tracks maintenance for PM
(CMMS)
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
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1312
Paint/Paint Touchup Staging
HARLEY DAVIDSON MANUFACTURING PROCESS
• Paint schedule and batching – managed outside SAP – a black box
• Paint touch up and staging is based on quality inspections
BUSINESS ISSUE
• Lack of inventory visibility and rework times – es-sentially an independent not integrated operation
SAP SOLUTION: SAP MII
VALUE FOR HARLEY
• Provide inventory visibility, rework times etc. for staging for fabrication (SAP MII
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
![Page 8: Harley Davidson - オルタナティブ・ブログ Davidson - Walking Guide.pdfHARLEY DAVIDSON MANUFACTURING PROCESS • Stamps VIN to the frame • Start of the use of carts to transport](https://reader033.vdocument.in/reader033/viewer/2022041911/5e6799baf080382fe46930ba/html5/thumbnails/8.jpg)
1514
�I-/=�E��+0/>/<3+
HARLEY DAVIDSON MANUFACTURING PROCESS
• Area that provides performance management dashboards
• %>363D/.�,C�=29:�G99<�:/<=988/6�38-6?.381�=230>� supervisors, team leads etc.
BUSINESS ISSUE
• No real-time live data feedback on performance metrics
SAP SOLUTION: SAP MII
VALUE FOR HARLEY
• Gain insight into KPIs and order status (SAP MII)
SAMPLE PERFORMANCE MANAGEMENT DASHBOARDS
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
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17
VIN Stamp & Tank
HARLEY DAVIDSON MANUFACTURING PROCESS
• Stamps VIN to the frame • Start of the use of carts to transport components
to the work cells • Tank sub-assembly as well as electric components,
caps etc. built
BUSINESS ISSUE
• No ability to optimally schedule production
SAP SOLUTION: SAP ME, SAP MII, AUTOMATED GUIDED CARTS (AGCS)
VALUE FOR HARLEY
• Provides the routing and the execution control for the build process, tracking the build, and recording any non-conformance (SAP ME)
• Provides the real-time connectivity for inventory as well as coordination of the delivery of parts (SAP MII)
• Provides information to the automated guided carts (AGCs). VIN # is added to the cart and the route is pulled from PP and interfaced with SAP ME eventually through MEINT. Information is pro-vided by VIN # to load and move the frames and the tank pieces to the appropriate location to be welded in place. (AGCs)
• Monitor AGC battery levels and light sensors (monitoring movement) and tracks based on VIN # (AGCs) (SAP MII)
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
NEEDS TO BE CUT DOWN
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19
Assembly
HARLEY DAVIDSON MANUFACTURING PROCESS
• Bikes are assembled onto the frames with the tanks – belt, engines, sub-assemblies etc.
• �3H/</8>�A9<5�-/66=�+6981�>2/�+==/7,6C�638/�manned by operators with terminals are shown or-ders and order execution process
• IT support is available to provide any manual over-rides etc. to help drive order execution
BUSINESS ISSUE
• Inability to optimally schedule and execute produc-tion, including capturing non-compliance, genealo-gy tracking etc.
SAP SOLUTION: SAP ME, SAP MII
VALUE FOR HARLEY
• Consoles provide the routing and the execution control for the build process, tracking the build, and recording inventory consumption in real-time as well as any non-conformance (SAP ME)
• Time clock integration for labor tracking (SAP ME, SAP MII)
• Andon Board signal functionality is used at each work cell - each work cell plays a unique song when there is an issue (SAP MII)
• Provides the co-ordination of the lean supplier parts needed for assembly together with SAP ME – MEINT (SAP MII)
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
![Page 11: Harley Davidson - オルタナティブ・ブログ Davidson - Walking Guide.pdfHARLEY DAVIDSON MANUFACTURING PROCESS • Stamps VIN to the frame • Start of the use of carts to transport](https://reader033.vdocument.in/reader033/viewer/2022041911/5e6799baf080382fe46930ba/html5/thumbnails/11.jpg)
21
SAP Enterprise Resource Planning
PLant Maintenance
Inventory and Warehouse Management
Quality Management
Master Data Authoring and Engineering Change Mgmt
Production Planning
SAP Manufacturing Execution
WIP (Lot and Serial #) Tracking and Genealogy
Manufacturing Process Control
Defect Tracking and Resolution
Data Collection
Labor Trading
ME 6.1
*Inventory is referred to as Floor Stock in SAP ME
• Production Order (Shop) • Planned Order (Repetitive • Order Changes • Services Order (RMA) • �+>/<3+6l�6+==3F-+>398= • Serial Number (Product) • BOM • Routing • Operation • Work Center • HR�%=/<�'l�/<>3F-+>398 • Inventory1 Receipt W/Batch • Inventory1 Reservation • Inventory1 Locations • Equipment Scheduled Downtime • Quality Inspection Lot • Work Instructions • Alternate Components • Phantom BOM Components • Co- and By-Products
• Production/Planned Order Yield �98F<7+>398
• Production/Planned Order Scrap �98F<7+>398
• Production/Planned Order �+-5G?=2
• #/<@3-/��<./<�)3/6.��98F<7+>398 • Component Goods Movement • Parent Batch Number • !?+63>C��9>3F-+>398= • Equipment Unscheduled Down-
time • Equipment Usage • Inventory1 Return • Inventory1 Scrap • Inventory1 Unreserved • Inventory1 Locations • DC Batch And Batch Characteris-
tics • Serial Number (Components) • Quality Inspection Lot Results • Direct Labor • Routing
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23
Repair and Roll-Test
HARLEY DAVIDSON MANUFACTURING PROCESS:
• The assembled bikes are provided a roll-test and repaired based on any non-compliance
BUSINESS ISSUE:
• This capability did not exist. Typically bikes were <+8.976C�:?66/.�9H�>2/�638/=�+8.�>/=>[.<3@/8�,C�9:-/<+>398=�0965=�]�3./8>3F/.�+</+�90�<3=5�09<�38=?<+8-/�etc.
SAP SOLUTION: SAP ME
VALUE FOR HARLEY:
• Provides the test sequences for any non-compli-ance testing (SAP ME)
• <9@3./=�>2/�=/;?/8-/=�09<�</:+3<�98�+8C�3./8>3F/.�non-compliance (SAP ME)
• Inventory, genealogy, labor tracking etc. all done as part of the execution
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
![Page 13: Harley Davidson - オルタナティブ・ブログ Davidson - Walking Guide.pdfHARLEY DAVIDSON MANUFACTURING PROCESS • Stamps VIN to the frame • Start of the use of carts to transport](https://reader033.vdocument.in/reader033/viewer/2022041911/5e6799baf080382fe46930ba/html5/thumbnails/13.jpg)
25
Crate & Ship
HARLEY DAVIDSON MANUFACTURING PROCESS:
• Final bike/trike is crated and shipped
BUSINESS ISSUE:
• Lack of visibility of which VIN #s going to which trucks
• Inability to optimize by grouping based on vehicle type, location etc.
SAP SOLUTION: SAP ME
VALUE FOR HARLEY:
• �8.[>9[/8.�><+-5381�90�>2/�F83=2/.�,35/�>2<9?12�manufacturing based on VIN# (SAP ME)
RepairRoll-Test
Crate & Ship
Assembly
Paint
Paint Touch-up &
Staging
VIN Stamp
& Tank
�I-/=��E��+0/>/<3+
Paint StagingPress
(Fenders & Tanks)
Bend Frames.
Weld Frames & TanksLean Supplier Parts Market
IT Support
QA
Tank Leak
Test CMMSMaintenance
![Page 14: Harley Davidson - オルタナティブ・ブログ Davidson - Walking Guide.pdfHARLEY DAVIDSON MANUFACTURING PROCESS • Stamps VIN to the frame • Start of the use of carts to transport](https://reader033.vdocument.in/reader033/viewer/2022041911/5e6799baf080382fe46930ba/html5/thumbnails/14.jpg)
27
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