Analyze Vehicle Flow from Point of Origin to Vehicle Shipping/ Processing Operations
Toyota Logistics Services (TLS) is responsible for coordinating the shipment of new Toyota, Lexus, and Scion vehicles from the dock in Japan to dealers in the United States.
TLS operates three West coast ports and two East coast ports. Vessels return to Japan for reload after vehicles are unloaded at each port in the US. At a port facility, vehicles are stored in a First Point of Rest (FPR) for processing before being shipped to dealers. A Final Quality Assurance (FQA) inspection is the last stage before the vehicles are ready to be delivered to dealers.
In order to analyze the vehicle flow from Japan through its US Ports, TLS required a Vehicle Logistics Simulator that would model Toyota’s East and West coast vehicle shipping and processing operations.
Visual8 developed a Vehicle Logistics Simulator of Toyota’s vehicle supply system to simulate one year of shipping operations under different operating scenarios in a risk-free environment. The model mimicked the large-scale logistics incorporating detailed shipping scheduling options, loading and unloading activities, product inventory tracking as well as unit processing and inspection operations.
A custom-designed, flexible interface allowed TLS users to quickly adjust system parameters and view the results of these changes. System parameters included:
- Shipping schedule,
- Simulation initial state,
- Number of vessels,
- Vessel unload times,
- FPR capacity by port facility,
- Number of vessel docks,
- Processing rates,
- Operating hours,
- Presence or absence of an additional port facility, and
- Level of inventory at each port facility.
The Vehicle Logistics Simulator provided reports through a graphical and spreadsheet-based interface which included:
- Daily CBU inventories by product type
- Macro level CBU inventory reports
- Vessel utilizations and breakdown
- Detailed berth conflict reporting
- Dock utilizations
- Processing facility utilization
- Overtime requirement tracking
The Vehicle Logistics Simulator enabled TLS to quickly determine the ideal set facility parameters and operating rules that would impact possible facility expansion projects.
Using the customized graphical display of the shipping and processing operations being simulated, TLS visually presented recommendations to senior management and other process stakeholders. The Vehicle Logistics Simulator adds a new dimension of strategic analysis as it facilitates the investigation of the supply chain performance under a wide variety of operating conditions, and serves as an excellent tool both for determining best practices and for demonstrating these practices and their impacts to system stakeholders.