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PACKING ENGINEERING DEP.
PLANING DEPUTY
DEC 2008
VISION
Designing the packing style for OEM parts which supplied by SAPCO
Designing and packing operations and export’s parts loading of industrial group of IKCO according to global standards
Consulting and offering services in the case of packing export’s parts
Consulting and offering services in the case of packing engineering to suppliers change of sapco
mission
1-preparing appropriate packing designs for all the under covered parts of 1-preparing appropriate packing designs for all the under covered parts of sapco in order to:sapco in order to:
1-1-decreasing assembling time in production line and optimizing area of line
1-2-keeping the quantity and quality of parts during transportation
1-3-making special facilities to feeding lines and storing parts
1-4-automated data transferring by parts packing
1-5-design packing style according to kanban & synchron and ordering system
1-6-decreasing packing damages
2- packaging for export to overseas (Designing & performing , loading ) by using 2- packaging for export to overseas (Designing & performing , loading ) by using international standardsinternational standards
33--Decrease the cost of packing for export by using new packing methods Decrease the cost of packing for export by using new packing methods and materialsand materials
1-7-decreasing packing costs
44 - -consultation to suppliers ikco group in the case of packing engineeringconsultation to suppliers ikco group in the case of packing engineering
Entrances &exits
Product groupsProduct groups
Exporting deptExporting dept
purchasing deptpurchasing dept
Logistic deptLogistic dept
ايران خودروايران خودرو
suppliersupplier
Overseas sites of IKCOOverseas sites of IKCO
Exporting deptExporting dept
Financial deptFinancial dept
Ordering and plan deptOrdering and plan dept
Logistic deptLogistic dept
Planning deptPlanning dept
IKCOIKCO
PACKING ENG.
PACKING ENG.
IKCOIKCO
Original processes
Designing packing style of OEM parts
Designing packing style of parts for export
Designing special metal pallet
Supervision of packing style of OEM
OEM parts packing style designs procedures
درخواست ارائهدرخواست ارائه
طرح بسته بندي )فرم طرح بسته بندي )فرم 106106))
ارائه پيش نويس طرح ارائه پيش نويس طرح بسته بنديبسته بندي
ارسال به ايران خودرو ارسال به ايران خودرو جهت گرفتن تاييد طرحجهت گرفتن تاييد طرح
بررسي توسط بررسي توسط
كميته بسته بندي ايران كميته بسته بندي ايران خودروخودرو
نهايي كردن طرح بسته نهايي كردن طرح بسته بنديبندي
$
$ $
صدور معرفي نامهصدور معرفي نامه
دريافت پالت دريافت پالت
اعالم طرح نهايي اعالم طرح نهايي
درخواست پروژه اي درخواست پروژه اي ارائهارائه
طرح بسته بندي طرح بسته بندي
پيشنهاد بهبودپيشنهاد بهبود
طرح بسته بندي طرح بسته بندي
چك ليستچك ليست تامين كنندگانتامين كنندگان ايران خودروايران خودرو
دريافت نتيجه بررسيدريافت نتيجه بررسي
تغذيه تغذيه خطوطخطوط
دريافت دريافت انبارهاانبارهاكاالكاال
مهندسي مهندسي لجستيكلجستيك
پشتيباني پشتيباني لجستيكلجستيك
مهندسي توليدمهندسي توليد
اطالعات مرتبط با پالت اطالعات مرتبط با پالت مورد استفاده در طرحمورد استفاده در طرح
packing procedures for export
Receiving BOM list of Receiving BOM list of exporting partsexporting parts
Receiving exporting Receiving exporting pack. designspack. designs
Receiving Receiving partsparts
Receiving exporting Receiving exporting planplan
$
$
$
Orderring parts Orderring parts according BOM & final according BOM & final
modificationmodification
packingpackingOrderring Orderring Packing ListPacking List
loadingloading
sendingsending
Providing Providing suppliessupplies
Suppling planSuppling plan
receiving BOM receiving BOMددmodificationmodification
Loading plan of Loading plan of modificationmodification
Special Metal Pallet and Structure Design Procedures
درخواست طراحي پالت درخواست طراحي پالت از طرف گروه هاي از طرف گروه هاي ساخت و خودكفائيساخت و خودكفائي
درخواست پروژه اي درخواست پروژه اي طراحي پالت طراحي پالت
درخواست طراحي پالت درخواست طراحي پالت مخصوص) سيكل مخصوص) سيكل
داخلي(داخلي(
درخواست طراحي پالت و درخواست طراحي پالت و سازه مخصوص سازه مخصوص
صادراتي) سيكل داخلي(صادراتي) سيكل داخلي(
ارسال نقشه جهت ارسال نقشه جهت ايجاد طرح اوليه پالتايجاد طرح اوليه پالتگرفتن تاييدگرفتن تاييد
بررسي نقشه توسطبررسي نقشه توسط
كميته بسته بندي ايران كميته بسته بندي ايران خودروخودرو
تغذيه تغذيه خطوطخطوط
دريافت دريافت انبارهاانبارهاكاالكاال
مهندسي مهندسي لجستيكلجستيك
پشتيباني پشتيباني لجستيكلجستيك
مهندسي توليدمهندسي توليد
ساخت نمونه توسطساخت نمونه توسطتاييد نقشهتاييد نقشه
ايران خودرو _ سازنده ايران خودرو _ سازنده
ساخت نمونه پالت ساخت نمونه پالت صادراتي صادراتي
بررسي نمونهبررسي نمونه
توليد انبوهتوليد انبوه
بررسي نمونهبررسي نمونه
توليد انبوهتوليد انبوه
Supervising procedure of OEM parts packing
درخواست تهيه چك درخواست تهيه چك ليست از طريق انبارهاي ليست از طريق انبارهاي
ايران خودروايران خودرو
درخواست تهيه چك درخواست تهيه چك ليست از طريق كميته ليست از طريق كميته
بسته بندي بسته بندي
درخواست تهيه چك درخواست تهيه چك ليست ليست
) سيكل داخلي() سيكل داخلي(
بررسي بسته بررسي بسته بندي ارسالي بندي ارسالي
سازندهسازنده
تهيه چك ليستتهيه چك ليست
$
$
$
اخطار كتبي به اخطار كتبي به سازندهسازنده
$
$
$
صدور نارضايتي صدور نارضايتي مشتريمشتري
پيشنهاد تغيير طرح بسته پيشنهاد تغيير طرح بسته بنديبندي
THE MOST ACTIVITIES & DONE PROCESSES
OEM parts Packing design
Designs of offered packingDesigns of offered packing
1250
1100
14201350
1654
1500
1839 1800
1435
1900
0
500
1000
1500
2000
1383 1384 1385 1386 1387
سال
تعداد واقعي طرح بسته بندي تعداد برنامه
05
1015202530354045
1383 1384 1385 1386 1387سال
تعداد طراحي و اصالح پالت
Special designed palletsSpecial designed pallets
2026
44 46
38
20
Establish system of receive packing design recommendation from Establish system of receive packing design recommendation from suppliers suppliers
Elimination of recommendation letter for Packing DesignsElimination of recommendation letter for Packing Designs
Establish Paperless System for OEM parts packing designEstablish Paperless System for OEM parts packing design
Optimization of process for Packing Optimization of process for Packing Engineering DesignEngineering Design
Weight Reduction of Special Metal PalletsWeight Reduction of Special Metal Pallets
Lost Weight New Weight Old Weight Pallet Name
25 144.5 169.5 RE8
24.5 138.5 163 RC5
12.1 70 82.1 RC7
38 216.5 254.5 RE1
31.8 179.5 211.3 RE4
طرحهايبستهبنديقطعاتگروه Bتغييروضعيتازكارتني ميزانتجمعيتعداد
1387 بهسبديدرسال
0
200
400
600
800
1000
1200
دورهزماني
سبد
بهي
رتنكا
ازفته
ياير
غيتي
ندهب
ستبي
هارح
طاد
عدت
تعداد طرحهاي قطعات تغيير يافته
از كارتني به سبدي ) برنامه (
100 250 350 450 550 650 750 850 950 1000 1030 1080
تعداد طرحهاي قطعات تغيير يافته
از كارتني به سبدي ) واقعي (
137 309 342 443 550 630
خرداد تير مرداد شهريور مهر بان آ ذر آ دي بهمن اسفند فروردين ارديبهشت
نسبتبههدف
The Trend of Second Phase of Plastic Basket Project
بستهبندي طرح طرحهايبستهبنديارائهشدهبرايقطعاتفاقد ميزانتجمعيتعداد
درسال 1387
0
200
400
600
800
1000
1200
دورهزماني
شده
ئهرايا
ندهب
ستحب
طرداد
تع
ارائه طرح بسته بندي قطعات فاقد طرح ) برنامه اي ( 190 290 390 470 570 670 770 870 970
ارائه طرح بسته بندي قطعات فاقد طرح ) واقعي ( 203 346 443 470 575 675
خرداد تير مرداد شهريور مهر آبان آذر دي بهمن
نسبتبههدف
The Trend of New part for packing design
از تاريخ شماره فاز تا تاريخ تعداد برنامه ارائه تعداد طرحشده
تعداد سازنده
1 84/01/01 86/06/31 1000 936 1046
2 86/07/01 86/12/31 890 639 687
3 87/01/01 87/06/31 540 467 435
4 87/06/31 87/09/30 540 311 38
بازنگر)5ي(
87/05/20 87/09/30 672 130 180
Current Optimization and Future Current Optimization and Future ProgramsPrograms
1080 1080 PartPart Second Phase of Plastic Basket Project
EXPORT
Annual ReportAnnual Report
ID SITE NAME CLASS AUTO LEVEL ( SKD ) NUMBER OF SENT AUTO
(8 MONTH 87)NUMBER OF SENT
AUTO (8 MONTH 86)
1 VEN SAMAND SKD 0 2352 624
2 SYRSAMAND
SKD 0 1200 3024
3 SENSAMAND
SKD 0 144 48
4 AZ SAMANDLX SKD 1آ 288 912
5 BLR SAMANDLX SKD 1 408 192
6 EGY PEGOUT PARS CKD2 576 0
7 SEN SAMAND EL SKD 2 168 252
8 ALL OF SITE SAMAND & LX &
PARS SKD0/ 1/2/CKD2
5136 5052
PACKING COMPARISON AND SENDING PARTS DURING 8 MONTH 86-87
0
1000
2000
3000
4000
5000
6000
تعدادخودرويارساليهشتماههاول 87 2352 1200 144 288 408 576 168 5136
تعدادخودرويارساليهشتماههاول 86 624 3024 48 912 192 0 252 5052
SKD 0 SKD 0 SKD 0 SKD 1 SKD 1 CKD2 SKD 2 SKD 1/SKD 5
سمندمعمولي سمندمعمولي سمندمعمولي LXسمند LXسمند پژوپارس EL تاكسي & LXسمندمعمولي
ونزوئال سوريه سنگال آذربایجان بالروس مصر سنگال كلسايتها
PACKING COMPARISON AND SENDING PARTS DURING 8 MONTH 86-87
Annual ReportAnnual Report
Annual Report for Casting partsAnnual Report for Casting parts
0
2000
4000
6000
8000
10000
هشتماههاول -87 6141.477 2567.458 1.622 478.29 478.982 9667.829
هشتماههاول -86 4080.521 1971.945 180.778 316.341 399.251 6948.836
فرانسه تركيه ايتاليا برزیل تونس
40% ACRESING OF DURING OF 8 MONTH 87
PACKING COMPARISON AND SENDING CASTING PARTS DURING 8 MONTH 86-87
Improvement projects in export Improvement projects in export activitiesactivities
Decrease using PS foam at SKD0 level consignmentDecrease using PS foam at SKD0 level consignment..
Decrease using PS foam from ./18 cubic meter to ./14 cubic meter per carDecrease using PS foam from ./18 cubic meter to ./14 cubic meter per car
Decrease using PE foam at SKD0 level consignmentDecrease using PE foam at SKD0 level consignment..
Decrease using PE foam from 30/87square meter to 20/16square meter Decrease using PE foam from 30/87square meter to 20/16square meter
for each automobilefor each automobile
Improving Loading of export consignmentImproving Loading of export consignment
Decreasing number of tracks from 8 to 7 for consignment of Syria siteDecreasing number of tracks from 8 to 7 for consignment of Syria site
Decrease using PS on exporting pack’s level Decrease using PS on exporting pack’s level SKD5SKD5Decrease using PS for each automobile load from 6.2cubic meter to Decrease using PS for each automobile load from 6.2cubic meter to
5.8cubic meter by using retainable materials5.8cubic meter by using retainable materials
Improvement projects in export Improvement projects in export activitiesactivities
Decrease usage of wood in the export Decrease usage of wood in the export consignmentconsignment
Improving function of wooden pallets in the Improving function of wooden pallets in the
result of decrease using wood from 9.02 cubic result of decrease using wood from 9.02 cubic
meter for each consignment to 8.112 cubic meter for each consignment to 8.112 cubic
metermeter
Some of successful improving Some of successful improving projectsprojects
Packing Manual of OEM partsPacking Manual of OEM parts
Packing Manual for ExportPacking Manual for Export
Unpacking Manual for ExportUnpacking Manual for Export
Packing Manual of heavy and huge parts’ of CKD consignmentPacking Manual of heavy and huge parts’ of CKD consignment
Unpacking Unpacking Manual of heavy and huge parts’ of CKD consignmentManual of heavy and huge parts’ of CKD consignment
Tracking procedures and instruction of export consignmentTracking procedures and instruction of export consignment
Packing Manual of OEM parts by SuppliersPacking Manual of OEM parts by Suppliers
Increase number of packing load size from 48 to 96In-site loading & lashing of consignment for shipping (in 8 container) Reducing cost in lashing each container 130$ Reusing of wasted wood of CKD consignment imported to IKCO for export to overseas site of IKCOReducing packing costs by 30%Design foldable metal pallets for sending parts to site in short distancePallet management (Ex. reducing weight number of pallets)
Improvement projects performed in Improvement projects performed in current yearcurrent year
Increase packing capacity by :
Establishment of BODY PACKING Site in IKCO
Cost analysis of parts for OEM Establishment a new system for packing design of OEM parts by suppliers Guide booklet for operating of packing machine toolsPerforming a new version of quality instruction for exportDesign new structure for carrying 4 SAMAND car bodies by container to shipment to Venezuela
Improvement projects performed Improvement projects performed in current yearin current year
Improvement projects performed Improvement projects performed in current yearin current year
Implement HOSPITAL SYSTEM for critical parts of export consignment
Certificates & AcknowledgementCertificates & Acknowledgement
LETTER OF COMMENDATION ABOUT EXPORTING PACKING
FROM ITALY ARA CO.
LETTER OF COMMENDATION ABOUT EXPORTING PACKING
FROM SIAM CO.SYRIA
◄EXTENDING ISO14001 CERTIFICATEEXTENDING ISO14001 CERTIFICATE
Focus Area 1 – [Improvement of environmental performance through identification and replacement of recyclable raw material]
LETTER OF COMMENDATION ABOUT EXPORTING PACKING
FROM VALEO FRANCE
