Completely knocked down

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The term Completely Knocked Down (German literally "completely dismantled"; abbreviation CKD ) comes from the automotive industry and describes a method of manufacturing and marketing motor vehicles in which components and assemblies are delivered and only assembled into a finished vehicle in the importing country .

In addition to the shipping of assemblies and individual parts, almost finished vehicles are also exported as semi-knocked-down (SKD) or medium-knocked-down (MKD) vehicles; These SKD or MKD vehicles are only missing very few parts that still have to be installed. Over time, the SKD / MKD vehicles often become CKD vehicles (see below).

reasons

The main reason for CKD / MKD / SKD exports are mostly high import duties for vehicles that are ready to drive, while significantly lower import duties have to be paid for end products that consist partially or completely of individual parts or that are missing individual parts. Due to the high import tariffs, automobile manufacturers are more or less forced to procure as many parts as possible in the respective target country, which are therefore also referred to as local content or national content . As a result, part of the added value in vehicle production is generated in the respective country and at the same time a national supplier industry is built up with its own production knowledge. The proportion of local content and its increase over time is often part of the CKD contracts (see local content clause ). Another reason for CKD production is the relatively easy start of local vehicle production in emerging countries , with only a few vehicles and a few vehicle variants initially being produced. So the investments for the automobile manufacturer in the new market remain manageable. In addition, the local workforce can first get to know the final assembly and, as the level of learning and development increases, gradually take on additional work.

CKD degree of decomposition

The CKD degree of dismantling indicates which individual parts and assemblies of a vehicle (in which state of construction) are sent, from which the vehicle is then assembled in the importing country. In the case of a vehicle, the body can either be shipped from individual parts and already welded assemblies and assembled in a CKD plant, or the painted body shell is exported or imported as a whole. In the latter case, one also speaks of SKD or MKD vehicles. This saves the investment for a local body shop and the paint shop, which are the largest investments in automotive engineering. One example is the MAN Lion’s Coach , the body of which is exported from the plant in Ankara (Turkey) to Santiago de Querétaro (Mexico), among other places , where it is mounted on a locally manufactured CKD chassis for local sales.

If vehicles are manufactured entirely in the country of origin or if only details are left out in production, one speaks of CBU vehicles ( Completely Built Up ) or FBU vehicles ( Fully Built Up ). The term "dismantling" suggests that the vehicle is first assembled and then dismantled again, but this occurs only rarely or in exceptional cases. One example of this is the Mercedes-Benz Sprinter van , which is built entirely in Germany (Düsseldorf and Ludwigsfelde) for sales in the USA with the details typical of the brand as a Mercedes Sprinter and Freightliner Sprinter. The closed variants produced in Düsseldorf are partially broken down into bookings in Düsseldorf in the order before dispatch, i.e. H. The engine, axles, leaf springs, tank and cardan shafts (cardan shafts) are dismantled, assigned to the vehicle by labeling, packed and shipped separately to the body (this is placed on a wooden frame produced on site and screwed). Due to the interior height of the container, no variants with a super high roof can be shipped. The reassembly takes place in North Charleston . Since 2018, an enlarged plant in North Charleston has no longer just been assembled, but completely manufactured.

The degree of dismantling must already be taken into account during the technical development of a vehicle. Vehicles that have already been developed with a view to CKD production can be found e.g. B. in the programs of Fiat ( Palio , Siena ) , Škoda ( Fabia ) and Dacia ( Logan ) .

Determining the degree of dismantling is an essential process step in CKD processing, which must be closely coordinated with production in the manufacturing plants and the corresponding CKD assembly plant. The lower the degree of dismantling of a vehicle, the more assemblies or modules are shipped and the lower the assembly effort and the added value in the CKD assembly plant. The higher the degree of dismantling, the more individual parts are shipped and the higher the production share and the added value in the respective country and the easier it is to “localize” the parts.

Documentation of the CKD degree of decomposition

The degree of dismantling of a CKD / SKD vehicle can either be documented in the normal production parts list or in a separate CKD / SKD parts list . If the documentation is in the production parts list, the individual parts and assemblies to be delivered are e.g. B. identified by the respective CKD number concerned. In the case of documentation using a separate CKD parts list, either a separate CKD parts list is created for each individual CKD number or a parts list with several CKD numbers for each CKD vehicle model, in which only the parts and assemblies of a vehicle or vehicle to be delivered are created . of a vehicle variant are listed. Since each CKD number documents the degree of dismantling of a specific vehicle for a specific country, the CKD parts list must be adjusted accordingly if the 'local content' is changed. Correct documentation of the current degree of dismantling is not only important for production, packaging and shipping, but above all for the preparation of the transport documents and export papers, because if the delivery and delivery documents do not match the documents for the import permit, the entire delivery can be made be held in customs.

CKD set orders and single part orders

CKD vehicles can be described and ordered in different ways, which also affects the packaging and shipping of the parts. When ordering CKD sets, a distinction can be made between three types of order with which a CKD importer or the assembly plant can order the desired vehicle sets from the vehicle manufacturer:

  1. The CKD vehicle kit:
    Here a (more or less) complete vehicle is ordered with a single CKD vehicle number, for which the respective parts and assemblies are then delivered. Using the CKD vehicle number, under which the parts and assemblies are delivered and which can be seen in the shipping documents and on the packaging, you can see which parts and assemblies belong to a vehicle and have to be assembled in the CKD assembly plant. The CKD partner can then use the same CKD vehicle number to procure or manufacture the missing parts as 'local content'.
  2. The CKD parts set:
    Here, only certain parts / equipment items (for a vehicle to be completed) are ordered with a CKD set number. This means that different vehicle versions of a CKD vehicle can be ordered and manufactured in a CKD assembly plant.
  3. The mixed CKD vehicle / parts set:
    Here, for a CKD vehicle set, the different scopes of parts for different vehicle variants with different CKD set numbers are also ordered. The parts for the CKD vehicle kit form the basic vehicle, so to speak, which are assembled with the parts of the respective CKD parts kits for the respective vehicle model in the CKD assembly plant.
Different types of CKD record processing

A CKD vehicle set or CKD parts set is usually ordered as a 12 or 24 lot size for cost, transport and processing reasons. The entire CKD processing, from packaging to shipping, delivery and provision through to assembly, is then precisely tailored to this order lot size, which not only simplifies logistical processing, but also the entire administrative and financial process. These two order lot sizes can be implemented with packaging sizes of 3, 4, 6, (8) or 12 parts, which means that exactly the complete order quantity is always achieved, which makes operational management and control much easier. Exactly 12 or 24 identical vehicles are then assembled from the supplied parts, for which the correct number of parts is always provided in different packaging sizes. Although this reduces the number of possible vehicle variants, this is more of an advantage for the assembly process, product quality and employees, especially if the CKD assembly plant is located in a less industrialized country with less manufacturing industry.

In addition to the set order, which is vehicle-related, there is also the order of individual parts by the assembly plant, which no longer has a direct reference to the CKD vehicles and therefore has nothing to do with the classic CKD set order. In this way, missing or damaged parts or spare parts can and must be ordered. However, for reasons of cost and know-how, the pure parts order is also processed via the CKD packaging center, which in practice results in a mixture of set and parts processing. From a certain number of vehicles sold in the importing country and a correspondingly high number of items produced in the CKD assembly plant, CKD processing is switched from set processing to parts processing. In this case, the assembly plant is responsible for the timely ordering of the correct parts, order quantities and dates and must derive these numbers itself from its own CKD assembly program.

CKD packaging center

In the CKD process, the CKD packaging and the CKD packaging center play a special role, as the parts to be delivered must be specially protected and packaged due to the long transport route and various external influences. Ship transport in particular requires special corrosion protection or special preservation against any kind of environmental influences as well as special protection against vibrations so that the quality of the parts is not impaired during the long transport. This often requires the development of special packaging and transport containers as well as the use of special preservation and packaging techniques. The packaging center is also responsible for the consolidation of all delivery flows to ensure complete and on-time delivery. The tasks of the packaging center also include the preparation of all delivery and customs papers as well as the processing of other administrative, financial or IT-related questions, as well as the coordination and coordination of the activities of the (in-house) departments involved in the process, the parts suppliers and the logistics Service providers, transport companies and the CKD assembly plants.

CKD assembly plant

The CKD assembly plant is more or less the “counterpart” to the CKD packaging plant, because this is where the shipped parts and assemblies are assembled into a vehicle (see BMW plants ). The degree of dismantling of the vehicle is tailored to the respective infrastructure and technical equipment of the assembly plant as well as to the knowledge and experience of the employees "on site". In the case of small quantities, the vehicles can still be assembled individually as in a workshop; over time, production can then be converted to flow production and assembly lines, which then requires corresponding investments.

swell

  1. ↑ LEOs additional information: knocked down - dismantled. In: leo.org . Retrieved July 22, 2019 .
  2. ↑ Cf. R. Schulz, F. Hesse: The production network of the VW group ... Gabler Verlag, Wiesbaden 1999, ISBN 3-8349-1085-6 , p. 224 ff.
  3. ^ HJ Struck: The automobile industry in developing countries ... , Münster, 1995, p. 19 ff.
  4. ^ W. Herlyn: PPS in automobile construction. Hanser Verlag, Munich 2012, ISBN 978-3-446-41370-2 , p. 71.
  5. ↑ Katharina Kort: Mercedes attacks with a new Sprinter plant in the USA. In: Handelsblatt . September 5, 2018, accessed November 21, 2019 .
  6. ^ W. Herlyn: On the problem of mapping products with many variants in the automotive industry , VDI Verlag, Düsseldorf, 1990, p. 42
  7. ↑ See R. Schulz, F. Hesse: The production network of the VW group ... Gabler Verlag, Wiesbaden 1999, ISBN 3-8349-1085-6 , p. 226.
  8. ↑ F. Klug: Logistics Management in the Automotive Industry , Springer Vieweg, Berlin, 2018, p. 172, p. 371 ff.

literature

  • Wilmjakob Herlyn: PPS in automobile construction - production program planning and control of vehicles and assemblies Hanser Verlag, Munich 2012, ISBN 978-3-446-41370-2 .
  • Joachim Ihme: Logistics in Automobile Construction - Logistics Components and Logistics Systems in Vehicle Construction Hanser Verlag, Munich 2006, ISBN 3-446-40221-7 .
  • Florian Klug: Logistics Management in the Automotive Industry - Fundamentals of Logistics in Automotive Construction 2nd Edition, Springer Vieweg, Berlin 2018, ISBN 978-3-662-55872-0 , p. 328 ff.
  • Rudolf Schulz, Frank Hesse: The production network of the VW group and the supply of the overseas factories In: Ingrid Göpfert (Ed.): Logistics of the future. Gabler Verlag, Wiesbaden 1999, ISBN 3-8349-1085-6 , p. 211 ff.
  • Hans-Joachim Struck: The automobile industry in developing countries - illustrated using the example of "Nigeria" , Lit Verlag, Münster, 1995 (also: Nijmegen, Univ. Diss. 1995), ISBN 3-8258-2626-0
  • W. Herlyn: On the problem of mapping products with many variants in the automotive industry VDI-Verlag, Düsseldorf 1990, ISBN 3-18-145216-5 .
  • K. Richter. P. Hartig: Building global networks as a success factor in the automotive industry , in: FJ Garcia Sanz et al. (Ed.): 'The automotive industry on the way to global network competence', Springer Verlag, Berlin, 2007, ISBN 978-3-540-70783-7 , pp. 251-264

See also

Web links