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TAKATA supplies leading car manufacturers on time with Advanced Scheduling
février 2016
The TAKATA Corporation is a Japanese company, founded in 1933 and employing more than 36,000 people in its 56 plants in 20 countries in 2013. TAKATA operates in the automotive sector with the production of components and assemblies such as safety belts, airbags, steering wheels and other parts used in the interior of virtually all major automotive manufacturers in the world.

In Brazil, TAKATA has three plants, the largest located in the city of Jundiai, São Paulo. The Jundiai plant has a diversified production, producing parts and complete sets of safety belts, steering wheels, airbags and other plastic parts for different car makes and models.

The main challenge of production scheduling for TAKATA is to synchronize the production of the items and components, so that they are available for mounting assemblies, and to make deliveries on time with dates established by the leading automobile manufacturers in Brazil.

The challenge to deliver on time can be exemplified by how they work for Toyota, which operates the Milk Run system, where their truck visits TAKATA up to 3 times a day to load only items that will be used in the next hours in its assembly line, in order to work with virtually no inventory.

After years of intensive work divided into research, development, implementation, and testing, TAKATA Jundiaí chose SIMATIC IT Preactor Advanced Scheduling (AS) to assist in the detailed scheduling of their various internal processes. Before the use of Preactor, this challenge was very laborious and the results were not always as expected. The scheduling was done using spreadsheets with a lot of manual intervention, requiring a long time to schedule and re-schedule, which is common due to the characteristics of business and demand.

Coordinated by the Logistics team, under the management of Carsten Franke, deployment had the support of other areas of the business such as IT, Production and Industrial Engineering. The first team who spearheaded the project was formed by logistics / supplies, led by Nataniel Oliveira, logistics coordinator, with strong support from analyst Marcos Pauda; and the IT team, led by Rafael Angelo, with the support of manager Thiago Queiroz.

SIMATIC IT Preactor AS was initially deployed in the plastic injection area and integrated with the previous ERP (Enterprise Resources Planning) system. With the corporate decision to replace the previous ERP with QAD, Preactor remained as a solution for detailed scheduling and was linked with QAD from the beginning of 2013, and its use will be extended to other sectors of the company.

TECMARAN (Preactor Gold Solution Provider) was invited to lead the migration process and implementation of SIT Preactor AS in other areas of the company. Rafael Abreu, TECMARAN consultant responsible for the project, believes the Jundiaí unit of TAKATA should soon be a world reference site for other units of the company, "Our expectation is that Preactor AS will become the tool for all TAKATA units worldwide."

Between 2014 and 2015 the use of Preactor has been expanded to the paint shop and the production lines of steering wheels, seat belts and airbags.
Silvio Ciaramello, Leader of Production comments, ‘"For production, the implementation of Preactor APS was a breakthrough. I see it clearly in my department, injection plastic parts, which was the first to receive the tool. The visibility given by Preactor is essential. Previously, the Scheduler could only see production demand for one or two days. With the tool, we are able to plan for up to one week. Subsequently, we manage to optimize the amount of raw materials, production tools and setups. Takata will only benefit more with the use of APS in all areas.”