THE PLEX SMART MANUFACTURING PLATFORM

SUPPORT FOR BMW GROUP SUPPLY CHAIN REQUIREMENTS

You are a supplier to one of the most revered manufacturing companies in the world, known for impeccable quality, innovation, and operational efficiency. What comes with being a part of that rare group of companies is a set of high expectations from BMW of its suppliers. From the moment new business is awarded through end of production and service part programs, BMW sets the bar high with a set of core manufacturing principles, sustainability standards, and supplier requirements.

The good news is that BMW prioritizes supplier success as a priority in the relationship with their suppliers, and they provide a great deal of support in ensuring that success.

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BMW GROUP SUPPLIER REQUIREMENTS

BMW supplier evaluation is measured against a set of target values over the entire product lifecycle. Overall performance is tracked by BMW through the LPKM – Supplier Performance and Competence Management tool. Plex helps BMW suppliers achieve higher LPKM scores with built-in production controls and automatic part verification within the shipping process.

Plex also supports three key supplier requirements and a set of minimum quality feature requirements to ensure BMW supply chain success:

BMW Supplier Logistics – Production Requirements

BMW developed its Production Requirements to help its suppliers consistently achieve 100 percent accuracy in their processes for packing, labeling, shipping, and traceability of BMW products. The key to meeting BMW MPRs is adopting line-side processes with built-in controls that can prevent errors in real time.

There are many ways for a supplier to meet these requirements using Plex:

Shop Floor Control

• Real-time machine integration to supply accurate part number data and counts.
• Vision sensors to identify, count and verify parts; determine good vs. scrap; verify kitting; validate tools/dies.
• Tool validation to ensure correct tool is being used in the machine.

Production Control

• Automatic label generation from production activities (work in process and finished goods).
• Weigh scales ensure accurate dunnage.
• Control of non-standard packs (small lots) at end of run/end of shift.

Inventory Control

• Container serialization provides accurate inventory tracking, shipping, traceability.
• Automatic part verification during pack/repack operations.
• Part serialization controls piece counts, rework and repack; enables serialized traceability.

Operator Control

• Accurate production information is displayed to operators in real time.
• Full operator accountability maintained during the entire production process.
• Touchscreens are supported to display part number data and images; enable adjustment at packing, rework, etc.

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BMW GROUP SUPPLIER REQUIREMENTS

BMW Earned Label Support

BMW requires all parts being produced be labeled at the time of finished goods production. BMW requires that the labels be:

• Printed at the production line or in the work cell, using real-time data from the ERP system.
• Printed on-demand, not batch-printed in advance.
• Applied immediately as the containers are packed.

BMW wants to eliminate the problem of receiving mis-labeled parts from its suppliers but doesn’t want to waste time or increase its labor cost to inspect every part it receives.

BMW Supplier Logistics Requirements

BMW has set minimum requirements to ensure supply performance during ramp-up, series production, and aftersales. The minimum requirements include the capabilities spanning the following control areas:

• EDI
• Capacity Planning
• Production Control
• Sub-Supplier Management
• Good Receipt at Supplier Location
• Production
• Goods Output and Shipping

BMW Group Minimum Systems Requirements

BMW requires all suppliers to meet a base set of requirements in their procedures and processes. Plex meets these requirements as shown below.

BMW SQM Requirement

Plex Capability

Micro-Stoppage Analysis

Industrial IoT (IIoT) real-time monitoring at sensor and/or machine level to track, diagnose, and identify root cause

Overall Equipment Effectiveness (OEE) KPI Tracking

OEE calculations and alerts based on data automatically captured at production interfaces

Corrective Action System

Corrective action system fully integrated with problem control (8D) and ERP data

Operations Standards, Training and Process Job Qualifications

Control plans (PQCT), checksheets, document control Training & skills matrix, operator validation for machine training Part and process control

Process Control

PFMEA fully integrated with control plans (PQCT) and checksheets

Change Point Control

Parts, engineering change request, program management

Supplier Management

Supplier list, supplier audit, problem control, document control system, supplier ppap, supplier scorecards

Supplier RFQ

Supplier Management Inspection, Test & Calibration

Control plans, checksheets Gage control integrated with checksheet

Suspect & Non-conforming Parts and Abnormal Process

Real-time container tracking, rejection tracking Problem control integrated with deviation tracking Deviation tracking integrated with checksheets

Organization

Compliance module, document control system, workflow

Quality Systems & Policies

Customer PPM, internal PPM, supplier PPM problem control (8D), supplier returns, customer returns

Preventive Maintenance

PM maintenance, MRO supplies, tooling management, tool tracking

Lot Control and Traceability

Control panel, serialized inventory management Heat management Lot control