If It Moves, Scan It! The Sugar Foods Story Kerry White, Sugar Foods Ray Agrusti, Eagle Global...

If It Moves, Scan It!The Sugar Foods Story

Kerry White, Sugar FoodsRay Agrusti, Eagle Global Services

QAD Proprietary

SUGAR FOODS PRODUCTS ARE

CONSUMED80 MILLION TIMES

PER DAY!

#1 Supplier of sugar substitutes

#1 Supplier of powdered, non-dairy creamer

#1 Supplier of almonds

#1 Supplier of croutons and crunchy salad toppings

QAD Proprietary

SUGAR FOODS PRODUCTS ARE DISTRIBUTED TO MORE THAN

850,000 OPERATORS

Commercial Food Service Providers

Non-Commercial Food Service Providers

• Restaurants

• Hotels

• Colleges

• Health Care Facilities

Retail and Consumer

• Warehouse clubs

• Supermarkets

• Mass merchandisers

QAD Proprietary

Sugar Foods operates four manufacturing facilities, with another coming on-line later in 2008.

Bakery items

Takes sales orders; Produces dry items,

condiment type

Bakery and dry items

QAD Proprietary

Manufacturing Manufacturing in 4 Locations:

– Sun Valley, CA– Villa Rica, GA– Commerce, CA– Mazatlan, Mexico

Service the following markets: – Foodservice– Specialty Markets

• Office Coffee Services (OCS)• Vending• Convenience Stores• Membership Warehouse Clubs

– Retail– Mexico– and Beyond!

Sun Valley, CA (180,000 sq. ft.)(5 football fields)

Commerce, CA (250,000 sq. ft.)(7 football fields)

Villa Rica, GA (340,000 sq ft.)

(10 football fields)

Mazatlan, Mexico (70,000 sq. ft.)

(1.5 football fields)

QAD Proprietary

Challenges

Less than acceptable inventory accuracyMaximize efficiency and profitabilityLimited granularity in transaction historyUnidentifiable products with similar

characteristicsMeet compliance requirements for lot traceabilityPosition for future growth

QAD Proprietary

Meeting the Challenges: Phase 1

Implemented QAD Eb2.1in 2006– QAD recognized Sugar Foods with its “Rapid

Implementation Award” at Explore 2007– Discovery to GO-LIVE in 77 days

QAD Proprietary

Known Challenges – Specific to ADC

Inventory accuracy or a single location called “OT”• Inventory that’s “Out There” somewhere

Real-time information Elimination of manual logging of raw materials Track materials from receiving through production and

then shipping by means of an automated system that provides full lot traceability

QAD Proprietary

The Right Solution for Sugar Foods

Sugar Foods chose Eagle’s RF Express™ for QAD Enterprise Applications

Chose Intermec Corporation’s CK31 RF handheld devices

Chose Zebra Technologies 105SL bar code label printers for the shop floor

QAD Proprietary

Why Eagle?

Strategic QAD Partner since 1992Seamless integration with QAD EAProgress-based solution99% data accuracy or betterReal-time data capture without changes to QAD

codePersonal experience with Eagle’s solution– Ease of implementation and use– Hardware and device flexibility

QAD Proprietary

Phase 2: Leveraging QAD EAwith an Automated Data Collection Solution

“ERP system implementations have 50% higher benefits when integrated with an Automated Data Collection System.”

Gartner Group 2001

Began ADC of raw material data in Villa Rica facility in July 2007– Receiving– Material transfer– WIP production

Completed rollout of raw material in Sun Valley in September 2007

Completed rollout of raw material in Commerce in December 2007

QAD Proprietary

HOW DID WE DO IT? Made early determination that all items should be

tracked utilizing pallet ID’s with very few exceptions

Identified data that should be visible and scanable on all items (Label Definitions)

Identified material flow and drop-off/storage locations

Identified QAD transactions required to achieve maximum efficiency and traceability

Identified Eagle transactions

Labeled all possible storage locations (racks, floor, trailers, etc.)

Performed repetitious hands-on training with users

QAD Proprietary

CAN WE SEE UNDER THE

HOOD?

QAD Proprietary

QAD Proprietary

FG InventoryLocations

Receiving

RM InventoryLocations

MaterialTransfer


Manufacturing ProductionScanning

ProductionStaging Locations

RM Hoppers

PORPOMPOB

PTRTRN

PTRTRN

PDPTDPPTR

BKF

MaterialTransfer

PTR

EAGLE RF EXPRESS for QAD EA

AUTOMATED DATA COLLECTION SYSTEM

PROCESS FLOW DIAGRAM

Status/Expire Date ChangeLabel

Printing

PLBLBL

PSCIDM

PRVIBIIBL

PRVIBIIBL

PRVIBIIBL

Receiving

Material Handling

Production/Finished Good Inventory

Order Picking/Shipping

PPKPICSPK(PL)SLBPGN

UtilitiesIBIIBLSBIPRVPLOCNTCTICTRTCTTRCUNRUNIBCPBCV

QAD Proprietary

Receiving


MaterialTransfer



PORPOMPOB

PMVTRN

PMVTRNPDL

PRVIBIIBL

PRVIBIIBL

Receiving

UtilitiesIBIIBLSBIPRVPLOPDLCNTCTICTRTCTTRCUNRUNIBCPBCV

EAGLE RF EXPRESSFor QAD EA


PROCESS FLOW DIAGRAM(SUPPLY CHAIN)

Material HandlingLabelPrinting

PLBLBL

QAD Proprietary

EAGLE RF EXPRESS for QAD EA


PROCESS FLOW DIAGRAM(Production)

Manufacturing ProductionScanning


RM Hoppers

PDLPLO

BKF

LabelPrinting

PLBLBL

Material Handling

UtilitiesIBIIBLSBIPRVPLOPDLCNTCTICTRTCTTRCUNRUNIBCPBCV

QAD Proprietary

QAD Proprietary

KEYS TO SUCCESS? “Know the Flow”

Simplify the process

Provide as many tools as necessary

Reduce keypad entry

Review the process periodically

QAD Proprietary

Where do we go from here? Implement scanning of finished goods w/lot control

– Production recording using backflush transaction– Pallet transfer between inventory locations– Sales order picking & shipping

Inter-company transfers utilizing DRP

Meet specialized customer labeling requirements– UCC/EAN 128 labeling– RFID labeling– Link to ASN transaction

Implement all scanning functionality in Mazatlan facility

Turn on lot control for raw materials

QAD Proprietary

Kerry WhiteIT Manager, Villa Rica FacilitySugar Foods Corporation+1.770.459.5225+1.770.459.9863 (fax)[email protected] www.SugarFoods.com

Contact Information

Ray AgrustiSenior Product Consultant / Project ManagerEagle Global Services+1.973.838.5006+1.973.492.2758 (fax)[email protected] www.EagleConDev.com

RF Express™ for QAD Enterprise Applications is a trademark ofEagle Consulting and Development.

“QAD” is a registered trademark of QAD Inc.

All other products or Company names herein may be trademarks of their respective owners.

If It Moves, Scan It! The Sugar Foods Story Kerry White, Sugar Foods Ray Agrusti, Eagle Global...

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