Calculation of replenishment planning attributes for automobile assembly parts at assembly line. Assessment of impact of planning inaccuracy to the required safety stock of assembly parts. Client — OJSC KAMAZ, the biggest Russian trucks manufacturer.
Period: November 2013 – May 2014
Industry: Manufacturing
Client / Partner: KAMAZ / BearingPoint
Project objective
Calculate safety stock of component parts considering operational replanning of production
The main stages of work and characteristics of the model
- Development and matching the approach to modeling
- Conducting seminars with employees of OJSC KAMAZ
- Unloading, cleaning and processing of data for modeling, in-depth analysis of operating SAP PP module
- Development and verification of a simulation model on the AnyLogic 6 platform
- Calculating attributes of planning replenishment of stocks using the model
Model input data
- List of all configured products and their parameters
- Existing and suggested algorithms of safety stock forming
The main structural elements of the model
- Input data file of scenario in MS Excel format
- Simulation model with interactive presentation
- Data aggregation module that allows to generate MS Excel files with the simulation results
Model output data
- Service level and actual materials turnover in modeling period
- Safety stock rate needed for maintaining the target service level
Project result
- Safety stock rate is calculated for 1602 materials of «Rubber technical goods» and «Electric equipment» categories
- The dependence of the main conveyor supply service level on materials safety stock rate has been identified