Components Safety Stock Calculation Supported by Monte-Carlo Simulation for Kamaz

Components Safety Stock Calculation Supported by Monte-Carlo Simulation for Kamaz

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