intermodal logistics operation in ford otosan, turkey
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Intermodal Logistics Operation In Ford Otosan, Turkey. Recai IŞIKTAŞ Logistics Manager. Agenda. Ford Otosan Introduction Turkish Automotive Industry Ford Otosan’s Logistics Applications Ford Otosan’s Intermodal System. İSTANBUL. İNÖNÜ. 1982. 1959. KARTAL. KOCAELİ. - PowerPoint PPT PresentationTRANSCRIPT
Intermodal Logistics Operation In Ford Otosan, Turkey
Recai IŞIKTAŞLogistics Manager
Ford Otosan IntroductionTurkish Automotive Industry Ford Otosan’s Logistics ApplicationsFord Otosan’s Intermodal System
Agenda
KARTAL
Parts Dist. Center 1997
KOCAELİ
2000
İNÖNÜ
1982
FORD OTOSANİSTANBUL
1959
““Best Ford BAO Plant in Europe”Best Ford BAO Plant in Europe”2002-2002-20062006 FPS Audit Results FPS Audit Results
320.000 units annual production capacity Sea front location, integrated pier/terminal covering exports & BU imports. Transit & Transit Connect production Total of 340.000 m² covered area on 1.600.000m² land.
KOCAELI PLANT
0
50.000
100.000
150.000
200.000
250.000
300.000
1960
1961
1962
1963
1964
1965
1966
1967
1968
1969
1970
1971
1972
1973
1974
1975
1976
1977
1978
1979
1980
1981
1982
1983
1984
1985
1986
1987
1988
1989
1990
1991
1992
1993
1994
1995
1996
1997
1998
1999
2000
2001
2002
2003
2004
2005
2006
2007
Total Yearly Production of Ford Otosan
In 2000 production unit was 40.000, in 2007 Ford Otosan expecting 280.000 unit production. • Export oriented strategy.
• Kocaeli Plant.
Total Yearly Export of Ford Otosan
With the export oriented strategy of the Kocaeli Plant, the export volume of Ford Otosan has
increased from 33.000 in 2002 up to 190.000 in 2007
33.058
73.182
136.913
159.655
182.244 190.000
020.000
40.00060.000
80.000100.000
120.000140.000
160.000180.000
200.000
2002 2003 2004 2005 2006 2007
Improvement of Turkish Automotive Industry
Turkish Turkish Automotive Automotive Exports increases Exports increases every year every year (Million$)(Million$)
Industry Value Industry Value Industry Value Industry Value Industry Value Industry Value Industry Value Industry Value Industry Value1 Readywear 8.000 Readywear 7.551 Readywear 7.451 Readywear 7.489 Readywear 9.172 Readywear 11.517 Readywear 13.098 Readywear 13.699 Automotive 14.8762 Iron 3.000 Iron 3.082 Iron 3.330 Iron 3.961 Automotive 4.715 Automotive 7.191 Automotive 10.698 Automotive 12.794 Readywear 13.9873 Textile 2.600 Electric 2.610 Electric 2.792 Automotive 3.717 Iron 3.954 Iron 5.389 Iron 9.220 Iron 9.440 Iron 12.7384 Electric 2.600 Textile 2.565 Automotive 2.636 Electric 3.248 Electric 3.486 Electric 4.382 Electric 6.087 Electric 6.964 Chemicals 8.7855 Chemicals 1.800 Automotive 2.369 Textile 2.590 Textile 2.867 Textile 2.978 Textile 3.664 Textile 4.566 Chemicals 6.750 Electric 8.0676 Grain 1.700 Chemicals 1.774 Chemicals 1.891 Chemicals 2.193 Chemicals 2.680 Chemicals 3.579 Chemicals 4.007 Textile 4.861 Textile 5.5767 Automotive 1.664 Grain 1.220 Grain 1.178 Grain 1.378 Grain 1.150 Grain 1.521 Machinery 2.093 Machinery 2.666 Machinery 4.217
696.688
# of Vehicles 297.862 430.947 270.685 346.565 533.354 823.408 879.092 987.580
2005 2006
# of Vehicles 37.227 104.079 205.163 261.692 360.950 518.521 561.674
2001 2002 2003 2004No 1998 1999 2000
European Production in Countries
5.758
3.549
2.753
1.803
1.038
988
882
GERMANY
FRANCE
SPAIN
ENGLAND
ITALY
TURKEY
BELGIUMThousands
6.6.
Importance of Logistics Material Inbound
Logistics Finished Vehicle Outbound
Logistics
Main Production Location
Key Factor: Effective Logistics Management
That level of mass production requires a similar mass movement and handling.
Not to make this traffic to be a chaotic situation, the key is; Effective Logistics Management.
“The one who manages Logistics better will be one step ahead of the other.”
HOW FORD OTOSAN MANAGES THE OVERALL
SUPPLY CHAIN?
FORD OTOSAN Logistics
European Inbound – Consolidation Center
Cologne
Gölcük
• Materials from European Suppliers flow to Consolidation Center located in Cologne.
• % 85 of total inbound material transport from Consolidation Center (EDC).
• % 15 of material is directly shipped from suppliers.
From CologneDaily Volume : 3.300 cbm
Daily Loading : 40 - 45 units*
Yearly Loading : 11.000 units* * Swapbody, trailer, sea container
Stable Transit Time between the Loading and
Production Locations,
Additional Costs on road & instable market price
Environmental Effects,
WHY INTERMODAL SHIPMENTS ?
Jan Feb Mar Apr May June July Aug Sep Oct Nov Dec
TreylerIntermodal
I N T E R M O D A LIMPLEMENTATION OF
BASIC PRINCIPALS
Usage of durable packaging instead of expandable,
Usage of high cube equipment
Limited material handling
Short and stabile transit time
Traceability during transit time
Cost affectivity
Intermodal Transportation Mode
RouteSerbia
Route Romania
Route Route SloveniSloveniaa
Intermodal Routing • general route plan via Romania, Serbia or Slovenia• decision given according to cost and route performance
Transit time• train transit 5,5 days (terminal-terminal)• collection & delivery 0,5 days each
COLLECTION
TRAIN DEPART. TRAIN ARRIVAL
DELIVERYDELIVERY
DAYS
Mon. Tue. Wed. Thu. Fri. Sat. Sun. Mon. Tue.
GENERAL TRANSIT TIME SCHEME
PLANNED TRAIN
ARRIVAL
Advantages Of the Intermodal System
Costs affectivity, Stability of freight cost, Effective cube utilization, Reliable and stable transit times, Visibility & Easy control, Availability of equipment, Sensible to the environment,
Environment FriendlyBy motorway Koln-Kosekoy=2.754 km Average 63 km/h means 44 hours
12.000 voyage per year means
Harmful gases have not been exhausted per year.
CO - Carbon Monoxite 483 gr/h x 44 h = 21,25 kgHC - HydroCarbon 152 gr/h x 44 h = 6,69 kgNOx - Nitro Oxite 1150 gr/h x 44 h = 50,60 kgPM - Particule 23 gr/h x 44 h = 1,01 kg
CO - Carbon Monoxite 255.024 kgHC - HydroCarbon 80.256 kgNOx - Nitro Oxite 607.200 kgPM - Particule 12.144 kg
INBOUND LOGISTICS (MATERIAL)INBOUND LOGISTICS (MATERIAL)Global InboundGlobal Inbound
Air Transportation ModeAir Transportation Mode 1 % 1 %Trailer Transportation Mode Trailer Transportation Mode 37 % 37 %Intermodal Transportation ModeIntermodal Transportation Mode 60 % 60 % Sea ShipmentsSea Shipments 2 % 2 %
FORD OTOSAN Logistics
Year 2007Year 2007
International Van of the Year International Van of the Year FORD TRANSITFORD TRANSIT
““The one who manages The one who manages Logistics better will be Logistics better will be one step ahead of the one step ahead of the
other.”other.”