Manufacturing Futures Bill Keese, SVP R&D February 11-12, 2013 West Coast User Group 1.
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Transcript of Manufacturing Futures Bill Keese, SVP R&D February 11-12, 2013 West Coast User Group 1.
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Manufacturing Futures
Bill Keese, SVP R&DFebruary 11-12, 2013
West Coast User Group
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Disclaimer• This roadmap is for information only and
represents QAD’s current view of its product direction. None of the information should be interpreted as a commitment on the part of QAD Inc.
• QAD works closely together with customers, user groups and analysts in validating and updating the product direction. The product roadmap is therefore subject to change.
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“An Effective Enterprise is one where every business
process is working at peak efficiency and perfectly
aligned to the company’s strategic goals. ”
Effective Enterprise
New Manufacturing capabilities. “What’s in it for you?”
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Review key MFG functions • Understand the key roles in operations• Understand the business processes
involved• Understand what we are delivering• Understand “What’s in it for” each key role
Objectives
New Manufacturing capabilities. “What's in it for you?”
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Role Based access
New Manufacturing capabilities. “What's in it for you?”
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Materials Management • Master Scheduler • Material Planner • Production Scheduler • Buyer (Direct Materials) • Kanban Analyst
Production Operations • Production Manager • Production Controller • Production Supervisor • Shop Floor Operator
Purchasing • Purchasing Manager • Buyer (MRO, CAPEX) • Purchasing Clerk
Affected Roles ERP users in Operations
New Manufacturing capabilities. “What's in it for you?”
Inventory • Warehouse Manager • Warehouse Supervisor • Material Handler
•Inbound•Internal•Outbound
Quality • Quality Assurance Mgr • Quality Engineer • Quality Technician
Cost Accounting • Cost Accounting Mgr• Cost Analyst • Cost Accountant
Manufacturing (Process) Engineering • Manufacturing Engineering • Manager Process Engineer • Value Stream Manager
Product Engineering (R&D) • Product Engineering Mgr• Product Engineer • Document Control Clerk
Tools and Assets (EAM)• Plant Engineer • Tool Manager • Tool Engineer • Tool Handler
General• Plant Manager• Operations Manager (VP Manufacturing, Supply
Chain)
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Working with disconnected tools
Why are we not synchronized today?
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Stage
Capability
Scheduler
Production
MaterialsBuyer/Expeditor
Tuesday 9am: Updates today’s production schedule to accommodate rush order
Demand/Inventory Reports
Production Schedule (version C)
System Data+Production Schedule (version B)
System Data+
Production Schedule (version A)
Production Schedule (version A.1 Modified)
MRP Supplier Schedules
Manual Adjustments
Click For Next Point
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?
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Master Scheduler’s Challenge
New Manufacturing capabilities. “What’s in it for you?”
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Executives
Profits are slipping and our ROI must
improve; the stockholders are not
happy!
Manufacturing
There are too many changes! Provide
fixed schedules and the correct parts and delivery will improve.
Sales
Service levels are down. I need more
inventory! Whatever it takes to keep the customer happy!
Engineering
There’s a new product introduction
scheduled for the fall! But we need
more time for design!
Finance
There’s too much cash tied up in
inventory!
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• Make Supply = Demand- New orders/rescheduling as necessary and
feasible/order splitting- Balance flexibility with stability
• Ensure Smooth Flow and Sensible Sequence- Leveling and sequencing- Not automatic (respects time zones)
• Communicate Problems (and Solutions)- Silence is approval
Master and Production Scheduling Objective:
“Say YES and Mean YES”
New Manufacturing capabilities. “What’s in it for you?”
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• Measurements (KPI’s):- Improved Customer Service:
• On time deliveries• Reduced back orders
- Reduced Inventory Levels• Inventory turns• Reduced inventory investment
- Stable Manufacturing Schedule• Increased production efficiency• Reduced set up costs/time, esp. teardowns and resets• Reduced overtime costs
Are Objectives Being Met?
New Manufacturing capabilities. “What’s in it for you?”
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• Rebuilds Master Schedule- Aligns Supply and Demand
• Smoothes Demand by Type- Backward/Forward (Daily)- Average (Time Period)
• Production Leveling- EPEI- Capacity Constrained- Allocation
Constraint-Based Master Scheduling Tool
New Manufacturing capabilities. “What’s in it for you?”
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Auto-Level production line schedule - considering:
-Capacity Constraints
-Order Priorities
-Business Rules
MSW – Master Scheduling
Leveling Methods – “Allow me to simulate different plans to achieve an appropriate balance of on-time delivery and capacity and product mix.”
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Production Scheduler’s Challenge
New Manufacturing capabilities. “What’s in it for you?”
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Manufacturing
Labor/Machine resources not
available for 2nd shift – what are you going
to do about this?
Sales
Drops in a new high priority order due tomorrow, which
order can be moved?
Materials
You can’t change the schedule on short notice and expect the materials to be
available.
Finance
High variances to “plan” (extra set up,
downtime, labor), you need to optimize
your production schedule
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Click For Next Point
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Create an executable production schedule:
- Sequence production orders by key attributes to achieve operational efficiency
- Check material availability to confirm ability to execute schedule & release
PSW – Production Scheduling
Dynamic Component Status & Drill Down – “Enables me to create a production schedule I can be highly confident in to execute – knowing the materials will be there.”
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Establish schedule meeting both maintenance and scheduling needs:
- Review planned maintenance orders for responsible resources and start dialogue
PSW – Production Scheduling
EAM Integration – “Enables me to see maintenance planning around my resources - to start a dialogue - and monitor progress of when the work will be complete.”
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• Assign Need Date to orders• Master Schedule by Quantity to Complete• Production Schedule by Quantity to Start• Schedule Work Orders on Production Lines• Default BOM’s and Routings by Production Line• Create schedules for work orders• Schedule Management
- Consume Oldest Orders first, or Use Consumption Window
• Kanban/Lean Scheduling using Repetitive, MSW/PSW
New Features for the Schedulers
New Manufacturing capabilities. “What’s in it for you?”
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• Allocate /Pick Orders prior to Release• Issue or Backflush by component• Pick and Issue or Pick and Transfer by
item • Order or Bulk Picklists• Improved Order Sheets• Use same functions to manage Work
Orders or Repetitive Schedules• Work Center and Production Line Reserve
Locations• Location Availability Check
New Features for Production Control
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New Manufacturing capabilities. “What’s in it for you?”
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Material Planner’s Challenge
New Manufacturing capabilities. “What’s in it for you?”
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Manufacturing
Carry more safety stock in case of low
yields/ schedule changes. We have to meet our schedules!
Suppliers
Cannot ship when requested. Is it ok to
ship late? And please send us a
forecast for the next 3 months
Materials
No shelf space for excess materials. You need to reduce
safety stock
Finance
Inventory turn over is too low/ Inventory Investment is too
high. Need to reduce inventory
levels.
Subcontractors
What is the supply plan for sending me
materials?
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Material Planner – Day In the Life
New Manufacturing capabilities. “What’s in it for you?”
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Material Shortages
Monitor Material
Shortages
Internal Supply Chain Synchronization
“I need to check the shortages for the parts I manage and determine what I can or need to do about the shortages.”
Material Delays – expiring inventory
Shifting demand priorities
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Click For Next Point
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Material Planner – Day In the LifeOrder Component Status (Shortage)Both the Scheduler and the Buyer have visibility of the material shortage and the impact to the production schedule
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Material Planner – Day In the Life
New Manufacturing capabilities. “What’s in it for you?”
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GRC - ResizeToo Many Cards In
Kanban Loop
“Continuous improvement shows I have placed too
many kanban cards in the loop. I need to revise the
number of kanban cards in the loop so that they are correct for next month.”
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GRC
New Manufacturing capabilities. “What’s in it for you?”
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Material Planner – Day In the Life
New Manufacturing capabilities. “What’s in it for you?”
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Subcontract Supply
Subcontractor Supplied Company Materials
“ We are ramping up a new subcontract supplier and I need to give them a
supply schedule for materials supplied by us.”
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Click For Next Point
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Create subcontract supply plan:
- Shows supplier what materials supplied when
- Provides Inventory Traceability
- Provides for company or supplier ownership of material
Automatic supply plan creation - “Enables me to help synchronize suppliers, track what inventory is sitting at suppliers and debit or credit expenses related to materials supplied to supplier.”
Subcontract Supply*
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• New GRC order Policy for planning Kanban items
• Use Gross Requirements or MPS as source for Average Demand Calculation
• Model Subcontract Supply loops for supplying materials to subcontractors with Kanbans –
• Size Kanban loops using Workbenches or in batch mode.
New Features for the Material Planner
Manufacturing Summit – Subtle changes Big Impact
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Production
Real-Time SynchronizationNew Manufacturing capabilities. “What’s in it for you?”
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Scheduler
MaterialsExpeditor
/Buyer
• Visualized with in WB’s & Role Based Collections• Enabled through the CAC Component Check
Availability Engine (MRE) not (MRP)
1
Click For Next Point
Planning & Scheduling WB’s
Shortage Monitor /Purchase Direct
Manage Materials by Resource
Release Production by Resource
CAC ENGINE
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Key benefits or features• Integrated planning and scheduling tool set• Simulate changes in real-time• Reduce planning and scheduling time and complexity• Compress manufacturing response• Provide ability to create effective plans and schedules• Enable to be proactive• Constraint-based master scheduler function complements MRP calculation
”Make more effective planning decisions”
New Manufacturing capabilities. “What’s in it for you?”
Improved automation in master scheduling activities & improved visibility of demand, supply, and capacity allows master and production schedulers to focus more on exceptions and make better informed decisions faster
In core product(No additional
cost)
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Materials Management • Master Scheduler • Material Planner • Production Scheduler • Buyer (Direct Materials) • Kanban Analyst
Production Operations • Production Manager • Production Controller • Production Supervisor • Shop Floor Operator
Purchasing • Purchasing Manager • Buyer (MRO, CAPEX) • Purchasing Clerk
Affected Roles ERP users in Operations
New Manufacturing capabilities. “What's in it for you?”
Inventory • Warehouse Manager • Warehouse Supervisor • Material Handler
•Inbound•Internal•Outbound
Quality • Quality Assurance Mgr • Quality Engineer • Quality Technician
Cost Accounting • Cost Accounting Mgr• Cost Analyst • Cost Accountant
Manufacturing (Process) Engineering • Manufacturing Engineering • Manager Process Engineer • Value Stream Manager
Product Engineering (R&D) • Product Engineering Mgr• Product Engineer • Document Control Clerk
Tools and Assets (EAM)• Plant Engineer • Tool Manager • Tool Engineer • Tool Handler
General• Plant Manager• Operations Manager (VP Manufacturing, Supply
Chain) …
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Shop Floor Operator’s Challenge
New Manufacturing capabilities. “What’s in it for you?”
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Supervisor
We must meet to day’s schedule. You
need to be more productive.
Quality
Why are we having defects? How many
are you finding.? Show me the SPC
chart
Product Engineering
We need to implement a new revision. Use this
new spec.
Production Control
Schedule change due to material shortage. Make
these items first.
Tool Maintenance
We need access to the machine for two
hours for repairs
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• Set up machines, tooling• Inspect & Monitor machines• Record Production Activity• Product Quality Control• Packaging End-of-Line• Move Materials
Day in Life Shop Floor Operator
New Manufacturing capabilities. “What’s in it for you?”
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Shop Floor Operator– Day In the Life
New Manufacturing capabilities. “What’s in it for you?”
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DailyProduction Schedule
View Production Schedule
Internal Supply Chain Synchronization
“What’s my schedule today? Do I have the
materials and tools I need? What do I set up first?”
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Production Operation Activity Collection
New Manufacturing capabilities. “What’s in it for you?”
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• New UI’s for transactions. Work from a schedule to report activity.
• More intuitive UI flow , fewer transactions• Report Repetitive and Work Orders from
same UI• View schedules to be consumed.• Detail Allocations support component lot
backflush reporting.• Integrated Kanban/repetitive transactions
New Features for Shop Floor Operator
New Manufacturing capabilities. “What’s in it for you?”
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• Many enhancements to streamline receiving and picking processes• Ability to capture all material handling actions in real-time.
Key benefits or features• Packaging setup and ability to uniquely identify packs will reduce time in data collection• Label printing services integrated with material flow reduces costs• …
”Make users in shop floor more productive”
New Manufacturing capabilities. “What’s in it for you?”
Many enhancements to streamline material handling activities, will reduce handling time, increase inventory accuracy
In core product(No additional
cost)
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Materials Management • Master Scheduler • Material Planner • Production Scheduler • Buyer (Direct Materials) • Kanban Analyst
Production Operations • Production Manager • Production Controller • Production Supervisor • Shop Floor Operator
Purchasing • Purchasing Manager • Buyer (MRO, CAPEX) • Purchasing Clerk
Affected Roles ERP users in Operations
New Manufacturing capabilities. “What's in it for you?”
Inventory • Warehouse Manager • Warehouse Supervisor • Material Handler
•Inbound•Internal•Outbound
Quality • Quality Assurance Mgr • Quality Engineer • Quality Technician
Cost Accounting • Cost Accounting Mgr• Cost Analyst • Cost Accountant
Manufacturing (Process) Engineering • Manufacturing Engineering • Manager Process Engineer • Value Stream Manager
Product Engineering (R&D) • Product Engineering Mgr• Product Engineer • Document Control Clerk
Tools and Assets (EAM)• Plant Engineer • Tool Manager • Tool Engineer • Tool Handler
General• Plant Manager• Operations Manager (VP Manufacturing, Supply
Chain) …
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New Manufacturing capabilities. “What’s in it for you?”
Material Handling
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Receive
Put-Away / Store
Pick / Move
Make
InspectPack
Pick / Move / Ship
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• Unloading• Match & Receive • Transfer / Put-Away• Picking • Packaging & Labeling• Weighing / shipment data• Loading / dispatch shipments• Cycle counting• Account for all material
handling
Day in Life Material Handler
New Manufacturing capabilities. “What’s in it for you?”
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• New/enhanced Functionality- Packaging- Serialized data management- Warehouse – serialized inventory - Label printing services- Communication and reporting- Data Collection services
• Foundations- Native API’s for all key Inventory Transactions
• Expanded QXtend coverage• Ease of integration & support for data collection
Serialization - Building Blocks
New Manufacturing capabilities. “What’s in it for you?”
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With serialization material / packaging handling…- streamlines receiving and picking processes- Ensures all data collection of material handling can be done in real-time
Key benefits or features- Decrease transaction time / cost of material handling- Improved Inventory Record Accuracy- Improved quality in planning & scheduling- Increase Customer Performance / Reduce customer complaints- Comply with standards trading partners
”More productive material handling”
New Manufacturing capabilities. “What’s in it for you?”
Many enhancements to streamline material handling activities, will reduce handling time, increase inventory accuracy, increase quality while managing data with higher granularity to track & trace inventory in the supply chain
In core product(No additional cost)
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Materials Management • Master Scheduler • Material Planner • Production Scheduler • Buyer (Direct Materials) • Kanban Analyst
Production Operations • Production Manager • Production Controller • Production Supervisor • Shop Floor Operator
Purchasing • Purchasing Manager • Buyer (MRO, CAPEX) • Purchasing Clerk
Affected Roles ERP users in Operations
New Manufacturing capabilities. “What's in it for you?”
Inventory • Warehouse Manager • Warehouse Supervisor • Material Handler
•Inbound•Internal•Outbound
Quality • Quality Assurance Mgr • Quality Engineer • Quality Technician
Cost Accounting • Cost Accounting Mgr• Cost Analyst • Cost Accountant
Manufacturing (Process) Engineering • Manufacturing Engineering • Manager Process Engineer • Value Stream Manager
Product Engineering (R&D) • Product Engineering Mgr• Product Engineer • Document Control Clerk
Tools and Assets (EAM)• Plant Engineer • Tool Manager • Tool Engineer • Tool Handler
General• Plant Manager• Operations Manager (VP Manufacturing, Supply
Chain) …
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• Monitor changes in BOM / engineering data
• Write/Update Test/Inspection Procedures
• Perform Test/Inspections • Document results of testing and
inspections• Root cause / Track & Trace• Recommend corrective actions
Day in Life Quality Technician
New Manufacturing capabilities. “What's in it for you?”
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• New Quality module • Extend use of item attributes• Expanded to support
- Multiple tests for an item - Multiple test records for a quality order - Multiple test samples for a test record
• Automation in creation Quality Order/events
• Create Certificate of Analysis
Quality
New Manufacturing capabilities. “What’s in it for you?”
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• New features integrates and automates receiving and inspection processes• Ability to capture all inspections data in real-time• Capture Multiple Test criteria / results of test samples• Quality Documents (Items and test specifications ; test records, QO’s and CoA)• Integrated with new item Attributes
Key benefits or features- Decrease transaction time / reduce cost of tests- Improved quality Recording Accuracy- Ensuring non-conformance is detected at its origin within the same system- Improved track & trace capabilities (inventory transactions & attribute historical
data)
”Make Quality Technicians more productive”
New Manufacturing capabilities. “What’s in it for you?”
Many enhancements to streamline inspection with material handling & shop floor activities, will ensure compliance with quality policies and ensure have non-conformance data available in real-time
In core product(No additional
cost)
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• Provides a Flexible Capability to define descriptive attributes by Item to meet ever-changing Industry and regulatory needs.
• Provides ability to support item lot and serialization track and trace independently from each based on multiple packaging levels
• All fully integrated with order entry, receipts & shipments ensuring real-time data.
Key benefits or features• Scalable and flexible capability supports current and new Industry Requirements across different niches• Reduces Customizations and eliminates the need for 3rd Party Integrations or double entries, or Excel • Attribute specifications, capturing values b and validations by attribute during receipts, picking and
issuing
”Support for Industry Compliance”
New Manufacturing capabilities. “What’s in it for you?”
Serialization enables support for California ePedigree ActAttributes will simplify implementation Compliance requirements leveraging real-time data for decision-making Reduce customizations
In core product(No additional
cost)
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• QAD Item Attributes and Quality Control assist the Effective Enterprise by: - Supporting customer, quality, regulatory
compliance- Eliminating manual or external processes for
managing extended/unique item attributes- Allowing combining and splitting lots- Eliminating need for external quality tracking - Improving tracking and tracing
Item Attributes, Quality Control and the Effective Enterprise
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New Manufacturing capabilities. “What’s in it for you?”
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Materials Management • Master Scheduler • Material Planner • Production Scheduler • Buyer (Direct Materials) • Kanban Analyst
Production Operations • Production Manager • Production Controller • Production Supervisor • Shop Floor Operator
Purchasing • Purchasing Manager • Buyer (MRO, CAPEX) • Purchasing Clerk
Affected Roles ERP users in Operations
New Manufacturing capabilities. “What's in it for you?”
Inventory • Warehouse Manager • Warehouse Supervisor • Material Handler
•Inbound•Internal•Outbound
Quality • Quality Assurance Mgr • Quality Engineer • Quality Technician
Cost Accounting • Cost Accounting Mgr• Cost Analyst • Cost Accountant
Manufacturing (Process) Engineering • Manufacturing Engineering • Manager Process Engineer • Value Stream Manager
Product Engineering (R&D) • Product Engineering Mgr• Product Engineer • Document Control Clerk
Tools and Assets (EAM)• Plant Engineer • Tool Manager • Tool Engineer • Tool Handler
General• Plant Manager• Operations Manager (VP Manufacturing, Supply
Chain) …
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• 3 to 5 early Adopters- Multiple Industries- Knowledge Transfer - Managed by R&D
• 3 to 15 – Limited Availability - Multiple Regions- Internationalized - Managed by Services
• General Availability- Regional
Introduction Process
New Manufacturing capabilities. “What’s in it for you?”
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What’s In it for You?
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