Production Manager 3-2010
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production 3 / 2010 Journal for Logistics & Production manager Contents ► Title story Mobile data collection: Special solution for the Dakar Rally Through the desert with VW HP & PSI bytes P. 1 ► User reports PSIpenta ERP system in action at Simon Transparency at the press of a button P. 5 ► Products & solutions New release of the PSIglobal planning and control system Key figures for globally successful logistic networks P. 8 VW Motorsport PSImetals in action The benefits of simultaneous Mobile data collection: special solution for the Dakar Rally slab connection during hot rolling programme planning P.10 Through the desert with VW HP & PSI bytes ► An interview with The Dakar Rally is seen as one of the last remaining great adventures of the modern Dr. Andrew Zoryk about cooperation day and as the toughest rally in the world. In 2010, it ended with a historic treble between SAP and PSI Metals victory for Volkswagen. Three Race Touaregs on the winner's podium meant not An unrivalled turnkey solution only that they defended their title but that they went one better than the double for the steel industry P.12 success of the previous year. The fact that the success was achieved by diesel cars, as in the previous year, also makes it a truly historic win. This success was not ► Events just down to engine size and horse power – bits and bytes in the form of a software PSI Logistics gets involved solution also played their part. in Hamburg school project Successful packaging P. 13 On New Year's Day 2010, the Dakar Everything was asked of both man and Rally started in South America for the machine: The race covered 14 stages Training courses about PSImetals second time. 360 teams with motorbikes, through the world's driest desert, the Successful start to PSImetals quads, trucks and 132 cars set out on the Atacama, and the Andes, with altitudes University 9000-kilometre route through Argentina up to 4700 metres. Competitors also had ► Company News P.14 and Chile. ► Page 3 pproduction 2 manager News ticker Editorial +++ PSI Awarded Contract by Dear readers, SMS Siemag for Planning Module for Russian Steel Producer OMK – The pressure of competition is bread and butter to Delivery of the solution PSImetals both companies and athletes. It impels us to deliver top 5 Planning for the new heavy plate performances and reminds us to continually develop rolling mill at the Vyksa site +++ our products and consultation services further and to PSI Awarded to Deliver Operations adapt them to the conditions and demands prevalent Control System to the Rhein-Sieg in our markets. For PSIPENTA Software Systems Verkehrsgesellschaft mbH – Inter- GmbH this means not forcing ready-made software modal Transport Control System packages on companies, but instead finding solutions that meet their specific needs. That is precisely what we have done in the projects with (ITCS) covers central functions VW Motorsport and the Simon Group. +++ PSI Awarded Major Contract During the Dakar Rally, a mobile solution helps VW Motorsport transport all data and by Swiss Federal Railway SBB – processes to exactly where they are needed. This solution features mobile registration, New network control system for a which ensures that the service life times of the different components and the storage secure railway electrical supply +++ locations of the spare parts are always known, and preventive exchange can be performed PSI Awarded Contract by Cologne- – before there is a failure. Bonn Airport and Lufthansa – At Simon too, individually adapted software ensures transparency across all plants and Volume-dependent invoicing of sites at the press of a button and, among other things, enables preventive maintenance on the machinery. luggage handling with PSIairport/ See for yourself in this edition the benefits that tailored IT support can bring and how our BRS +++PSI Delivers New Net- customers become champions in their markets. work Control System for the City of Vienna – Wien Energie decides Yours faithfully, in favour of PSIcontrol +++ PSI Alfred M. Keseberg Awarded Contract from Arcelor- Managing Director Mittal in France – Production con- PSIPENTA Software Systems GmbH trol and material tracking for the rod and bar mill at the Gandrange SCHEDULE plant +++ 06/10–08/10 2010 Internationale Zuliefererbörse PSIPENTA/PSI (International Suppliers Fair), Wolfsburg, Germany Logistics Imprint www.izb-online.de Stand 3/310 Publisher: PSI AG 20/10–22/10 2010 27. Deutscher Logistik-Kongress PSI Logistics Dircksenstraße 42–44 (German Logistics Convention), Berlin, Germany Havanna Lounge/ 10178 Berlin (Mitte), Germany www.bvl.de Tiergarten 1 room Telephone: +49 30 2801-2029 26/10–28/10 2010 it&business, Stuttgart, Germany PSIPENTA www.itandbusiness.de Stand 5D56 Fax: +49 30 2801-1042 [email protected] 11/11–12/11 2010 STAHL 2010, Düsseldorf, Germany PSI Metals www.stahl2010.de www.psi.de Editorial team: Ulrike Fuchs, Anja Malzer, 11/11–13/11 2010 IPA – Kunden-Jahrestagung PSIPENTA Bozana Matejcek, Annett Pöhl (Annual Customers Conference), Munich, Germany www.psipenta.de Design: Ulrike Fuchs 30/11–01/12 2010 PSImetals User Group Conference, PSI Metals Printed by: Repro- & Druck-Werkstatt Krefeld, Germany 3/2010 ∙ production manager 3 pproduction manager ► Continued from page 1 to cope with fog, rain and sunshine, and temperatures up to 50° C in the shade. It will therefore come as no surprise that Volkswagen Motorsport Director Kris Nissen commented that the Dakar is no walk in the park – but instead poses a new challenge everyday that is enough to make you tremble. Anybody wanting to pass this test should make excellent and thorough preparations. Fitness alone is not enough to overcome the strains – the Race Touareg's engineering is also exposed to extreme demands. Issues such as material quality and quality management with mileage recording are therefore put under increased scrutiny on the part of those responsible. A mobile solution By 2002/2003, Volkswagen Motorsport had developed so far within the group that it had to stand on its own "stable system feet" in order to best support the Polo Cup, for example. At that time, software modules developed by the Berlin company PSIPENTA Software Systems GmbH were being used, which During the rally, the service team gets precise information about the service life of al the components and is implemented the core business processes able to keep a constant eye on the mobile spare parts store on the service trucks. Source: VW Motorsport such as procurement and production and tracked the costs of projects like the drawn up in 2007/2008. By means of logistics processes. The mobile system Polo Cup and the Dakar Rally. The PSI a feasibility study, the joint project sits on top of it and transfers data and solution has since then been introduced ultimately led to the creation of a mobile processes to where they occur, in other as ERP software and supports commercial solution, which was specially designed words straight to the race track or the processes such as order administration for use during a race and directly on site. Volkswagen tent, and uses them there and materials management. It also led to the introduction of the two- without a connection to the headquarters The use of software intensified as the dimensional data matrix code, which as an asynchronous solution. All the benefits became ever clearer. When it is used in production, in automotive information and processes, that can came to problems with material quality, manufacturing and in mail delivery, for normally be accessed online or via a it made sense to combine quality example. WLAN, must be appropriately defined management and material management and stored on the mobile devices, such processes. As a consequence, the Independent of the headquarters as handhelds or laptops. motorsport managers around team During the Dakar Rally, VW Motorsport director Rainer Fleischmann looked The PSIpenta ERP system from the uses so-called 'service trucks' as escort for solutions together with the Berlin parent company forms the basis, with vehicles, which transport the tools, tyres software supplier. The first plans were all stored master data and the optimised and spare parts for the Race Touaregs. 3/2010 ∙ production manager pproduction 4 manager The service team uses the PSI software to determine where each part is stored in the truck even before it is loaded and stores the part and storage location on the mobile devices. For identification purposes, the parts are labelled with serial numbers on fixed tags using data matrix codes. The software therefore exactly depicts the contents of the truck, thus making the service team autonomous for the duration of the race; in other words, independent from the central system. All bookings that are normally directed through headquarters now take place exclusively on site. Once the team's last car passes the finish line, the data can be extracted and immediately sent via an Internet connection to the headquarters' system, which automatically analyses With the help of a barcode scanner, each replacement of a part is recorded. Source: VW Motorsport it. In the case of the Volkswagen team, compared with previously, this database of target service lives, which in decentralised storage organisations improvement alone results in a time shows in advance which parts will through to implementing "counter saving of four to six weeks when working probably not survive the planned operations" in the spare parts business. on the material planning data for the distance of 9000 kilometres. The team is In these cases, all data is collected in the next race. thereby able to specifically monitor every mobile solution, whilst the commercial vehicle, both on test drives and during booking is done in the central system. Knowledge database for mileage- race breaks, and dismantle and replace As a result, data is reliably collected related parts parts as part of preventive maintenance.