&-Yap Auto Parts

Yapu has the industry's leading fully automated production line, applying SAP ERP, MES, SRM and other systems for digital management. It has recently introduced intelligent equipment such as AGVs and suspension chains to further improve the warehouse's storage capacity utilization and picking efficiency.

The original SAP had problems such as low level of refined management, manual accounting for manual ingredients, out-of-synchronization of accounts, and inability to effectively collaborate with suppliers. In order to improve the intelligence and visualization of warehouse management, Yapp teamed up with Fuller to introduce the FLUX LES + WMS solution to jointly create a digital factory and achieve intelligent driven distribution.

The FLUX LES + WMS solution will first be applied to Yapp Automotive Parts’ Shanghai factory, and will be gradually expanded to Yapp’s 18 domestic and 8 overseas production bases.

Management scope: Intelligent pulling and AGV distribution of raw materials, intelligent pulling and AGV distribution of semi-finished products, DVS sorting and delivery of finished products
Apply Fuller Products: FLUX WMS, FLUX LES, FLUX DATAHUB
docking system: ERP(SAP), MES, SRM, DVS, WCS
docking device: AGV, suspension chain

1. Standardization of barcode management

Dozens of Yap's suppliers did not use unified incoming material labels before, and most of them used one-dimensional codes, which had poor scalability and made it difficult to achieve refined management of the warehouse. Fuller Solutions redefined and designed 2D barcode labels for Yapp, and barcoded 100% of WMS-managed materials and 100% of material rack pallets. WMS pushes material PFEP information to SRM to realize unified management of master data, and through SRM docking, supplier incoming material labels are unified, and suppliers print box labels and pallet labels themselves.

2. Efficient supplier collaboration

Since the original supplier's delivery packaging was not uniform, after receiving the goods, the warehouse needed to change the packaging and then manually receive the goods in SAP, which was inefficient, error-prone, and the information feedback was not timely. Fuller's solution connects WMS with SRM systems and promotes supplier packaging standardization. Suppliers print and affix box and pallet labels. After arrival at the warehouse, goods can be directly scanned and received. The docking of WMS and SAP enables real-time accounting processing, improves work efficiency, and achieves visual management through arrival information boards.

3. Material life cycle management

The original inventory management through SAP was not precise enough. It could only manage the inventory location and total quantity, but there was no management of storage locations, batches, first-in-first-out, etc. Fuller's solution realizes refined management of the entire life cycle of materials, and adds box code and pallet code management in the material + batch dimension. Box code scanning is used to manage the entire process of material receipt, distribution online, and consumption, and automatic verification of first-in, first-out is performed through scanning.

4. Intelligent pulling and automatic distribution of materials

Under the original management model, Yapp's warehouse managers regularly delivered materials to the line according to the production plan, and then manually made accounts in SAP after the materials were delivered. This batching method could not adapt to the increasingly flexible production plan, and manual operations were time-consuming and laborious. The FLUX LES+WMS solution supports customers to realize intelligent pulling of materials, and combines AGV and suspension chain equipment to achieve automatic distribution. The new solution supports two modes: manual pulling and system automatic pulling. The LES system automatically generates material pulling orders based on the work order BOM and lineside inventory consumption rhythm, and guides the automatic distribution of AGV operations online. ； The E2XX welding assembly (semi-finished product) is automatically put on and off the shelf through a suspension chain under the guidance of the system.

5. High-level shelves and AGV automatic operations

Yap Warehouse originally used low-level shelves and ground storage locations, which resulted in low warehouse utilization. The loading and unloading operations were performed by manual forklifts, resulting in low operating efficiency. Under the new plan, the parts warehouse uses 4-layer high-level shelves, which are equipped with AGV automatic operations. WMS guides AGV operations based on receiving information and pulling information to complete the tasks of putting on and taking off shelves, effectively improving operating efficiency and storage capacity utilization.

6. Physical/account synchronization

Under the original management model, materials were sent and received through paper documents, which were regularly summarized and recorded in SAP. The physical goods and accounting were not synchronized. The new solution connects WMS with SAP and MES, and the movement of goods is completed through scanning. WMS is linked with SAP to post accounts in real time, receive MES offline information in real time, automatically enter the warehouse, automatically report work, automatically backflush, and achieve account-actual synchronization.

7. Visualize the entire operation process

Originally, work tasks were assigned mainly through paper documents and WeChat work groups, which resulted in high communication costs, lagging information, and low efficiency. Fuller Solution helped Yapp realize the visualization of the entire operation. It configured receiving boards, pull boards, AGV boards, inventory boards, hanging chain boards, etc. in different areas of the site. Operators can view task dynamics in real time through the boards in their own areas, and managers can also see the operation status at a glance.