AIRBUS Case Study

Paris
5 May 2010

2007
Constraints
Airbus
Work-sharing
Scope of work = 2 final assembly lines, 11 design & manufacturing
facilities in Europe
80 warehouses & +/- 20 major suppliers (>1mio )
X

Forward
Fuselage
Vertical
Tailplane

Out of scope
X

Wings

XXX

Aft
Fuselage
Vertical
Tailplane

Nose
fuselage

Horizont
al Tail
plane
Belly
fairing

AIRBUS Case Study

Centre
fuselage

Pylon

5th May 2010

p. 2

The bottom-up KN Value Proposition

Product & Logistics

segmentation

Flow chart

Initiative Portfolio Development

Ideal scenario identification

and calculation
Constraint
Assessment

As is scenario identification
calculation

Realistic scenario identification

and calculation
Cost calculation & Gap
analysis
Business case on Ideal and
realistic scenario

Implementation plan

KN Business Migration Methodology

Phase
Phase
Phase
Phase33
Phase11
Phase22
Preferred
Stabilization
Stabilization Transition
Transition Preferred
Solution
Solution
(Continuous
(Continuous
Improvement)
Improvement)

AIRBUS Case Study

5th May 2010

Key Value Drivers of the Kuehne + Nagel Solution

Consolidation of Logistics
Operations into
6 Regional Hubs in D, F, ES, UK

Deployment of a single WMS

system to reduce complexity,
cost and enable standardization
of processes

AIRBUS Case Study

Consolidation of Service Providers /

Implementation of a single Lead Logistics
Provider

Introduction of standardized processes

based on best practices
Leverage outsourcing
opportunities for non-core
services in a standard blueprint
across all sites

5th May 2010

Integrated Project Team taken from existing KN organization

Central team (plateau)

Local teams
- Local surveys
- As is flow design
- Local scenario costing
- Etc..
AIRBUS Case Study

Re-engineering teams
- Scenario build-up
- To be scenario costing
- Value proposal design
- Road mapping
5th May 2010

Kuehne
+ Nagel transformation vision
Airbus
Work-sharing
6 Regional hubs in Europe
120.000 sqm / 1500 FTEs
X

Out of scope
Forward
Fuselage
Vertical
Tailplane

Wings

XXX

Aft
Fuselage
Vertical
Tailplane

Nose
fuselage

Horizont
al Tail
plane
Belly
fairing

AIRBUS Case Study

Centre
fuselage

Pylon

5th May 2010

p. 6

Kuehne + Nagel scope of work for AIRBUS

Section Handling

Delivery to FAL

Delivery to Point Of Use

Kitting & Order Preparation

H&F Ordering +
Stock management

Reception & Quality control

AIRBUS Case Study

Delivery Center

Cut to Size &

Sealant mixing

Storage

5th May 2010

p. 7

Kuehne + Nagel mirror AIRBUS supply chain organization

Steering
Committee
Central Level
Direction
Monitoring
Decisions

Local Level
Requirements
Execution

AIRBUS Case Study

Central Team

Stakeholders
Broughton
Nantes
St. Nazaire
Toulouse FAL
St. Eloi
Getafe
Illescas
Puerto Real
Bremen
Hamburg
Hamburg FAL

LLP Control
Tower

Operations
UK Hub
Northern France
Hub
Southern France
Hub
Madrid Hub
Southern Spain
Hub
German Hub

5th May 2010

AIRBUS / Kuehne + Nagel Governance Model

Steering
Committee
Operational Steering
Committee
Engineering / IT / Method

Local Steering Committees

South France

West France

Broughton

Hamburg/Bremen

Central Spain

South Spain

Individual Implementation & Re-engineering Projects

AIRBUS Case Study

5th May 2010

Transition phase from project team to operational team with a single

target : Secure the operation
Transition Phase
Gradual Transition from
Commercial team to Go-Live
Commercial team still in
charge of AIRBUS Key Account
Management & Operational
steering
HR

Review with Incumbent

Go-Live
Operational Team
Implementation
Commercial Team

AIRBUS Case Study

5th May 2010

Transformation Plan during implementation (i.e Toulouse)

September 2008

December 2009

BLAGNAC

BLAGNAC

JLL

JLL

ST ELOI

ST ELOI

SEOR

SEOR

TIT

TIT

CLEMENT ADER

CLEMENT ADER

L. BREGUET ATHOS

L. BREGUET ATHOS

HARDWARE
& FASTENERS

HARDWARE
& FASTENERS

7P2 BOOKING

7P2 BOOKING

EUROCENTRE

EUROCENTRE

Take over of over 360 employees (providers & AIRBUS) in one year with 4 different collectives agreement
and 5 different HR policies
Smooth transition with 0 day of work stoppage
AIRBUS Case Study

5th May 2010

p. 11

Transformation Plan during implementation (i.e Nantes & St Nazaire)

Many to Many

AIRBUS SNZ

Log
Suppliers

One to One to Many

Truckers

AIRBUS
NTE/SNZ
Supply Chain
Team

AIRBUS NTE

AIRBUS
Procurement
Tier1
AIRBUS
Prod NTE/SNZ

Tier1

Log
Suppliers

Sharing best in class processes & reapplying projects

Strategies and Processes are standardized
Quick Return On Investment is proven
Centralization allows to create a central know-how repository (best practices, methodologies, statistics,
KPIs..)

AIRBUS Case Study

5th May 2010

Logistics Hub construction for line feeding in Nantes & St Nazaire :

18.000 sqm

Final Project
Total surface
18.000 sqm
(3 x 6.000 sqm)

Total surface

AIRBUS Case Study

Ground

Mezzanine

18.000 sqm

1.800 sqm

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p. 13

Lean Logistics Projects Central Coordination, supported by KN and

Freelog
A32 0 P O LAR IS

Macro-planning

Steering committee management :

Planning validation

Cross fertilization

Savings tracking set up

Gains

Cots

Planning
A

Mise en KB de
p ices

9 8 k /a n

n. c

Rorga nisa tion

K B CM S

1 1 k /a n

n. c

Divers
AIRB US S.A.S. All rights r eserved. Co nfidentialand proprietary do cument.

Lean Day within Logistics organisation

with 2 workshops :

Bypass flew management

Hub project impact

Thme

N ouveaux besoins?

On going weekly flash report follow up

Li nda Gascoi n - Lean Logi stic project - SNZ

Pa ge 1 0

Tableau de bord Lean Logistique 6 JUILLET 2009

Flash Report A340 Polaris

Retard

# actions
En cours

Finies

A320P

A340P

nc

nc

nc

A320C

Agenda

TMT-logistique-lignes : qui paie q uoi?

Projet Hub + questions
Avancement des actions en-cours
Revue pa r programme)
Actions coordinatio n
Actions identifies lors du Lean Day n1
-

Le xique

A telier d am lioration de la g estio n de s m ises jou r de con tena nt (USM)

AIRBUS S.A.S . All rights r eserved. Co nfidentialand proprietary do cument.

5.
6.

: 10h00-10h30
: 10h30-12h00
Flux seco ndaires (peut-tre intressant seulement pour Comte)
Prochaines tapes et conclusion
: 12h00-12h30
Djeuner

Li nda Gascoi n - Lean Logi stic project - SNZ

AIRBUS Case Study

Page 2

AIRB US S.A.S . All rights r eserved. Co nfidentialand proprietary do cument.

: 9h00-10h00

3. Pau se
4. Atelier
-

Mallettes
CMS
PA/PAV

: 8h00-9h00

2.

A340C

A380C

na

na

na

GLOBAL

10

11

15

Linda Gascoin - Lean Logistic project - SNZ

AIRBUS S.A.S. All rights r eserved. Co nfidential and proprietary do cument.

1. Prsentations

Gains
Responsable

NC / JO

Date

-

6/07/2009

# actions

12

Avancement gnral
Kits pices

Rsultats de la semaine coule

 PA :
 Prparation des kits au MSN 90%, reste la partialisation
des
gammes
 Ralisatio n du plan de rimplantation des kanbans par
opratio n
 Pavillo n :
 Dploiement des mallettes
visserie: nombreux
dysfonctionnements, corrections des mallettes
 Aid e la prparation des mallettes
 Lancement de ltude sur le circuit des ferrures de hissages
-et transport
 1391
 Prsentation des axes du projet 1391
Points en suspens et difficults

K anban

Flux
secondaires

Actions planifies sur la semaine suivante

 PA :
 Formation la modification des adressages kanbans
 Partialisation des gammes par la prpa
 Pavillon :
 Dploiement des mallettes visserie : 3eme vague de 4
oprations
 Modifications des kanban pices du poste 1361 li aux
travaux dinstallation des portes sur le poste
 1391
 Remise jour des panoplies CMS
 Dcoupage des gammes par kit avec les TP

Nouveaux sujets identifis A intgrer

 Passage des pices en USM en Kanban

 Livraison des mallettes visserie poste 1381
Page 1

Linda Gascoin- Lean Logistic project - SNZ

Page 4

5th May 2010

St Eloi Production Moving Line

AIRBUS & KN joined work to set-up the

MOVING LINE project for pylons
Optimization of logistics flow :
From 11 static lines to 1 moving line
MDUs optimizations
Replenishment process based on tact
times
Reduction of missed item at line level
Optimization of workers productivity
Bring correct parts at correct place and
correct time -

AIRBUS Case Study

5th May 2010

Merci beaucoup Thank you Vielen Dank Muchas Gracias