qad planning and scheduling workbenches carianne nieuwstraten, product manager, qad. inc ben...

QAD Planning and Scheduling Workbenches

Carianne Nieuwstraten, Product Manager, QAD. IncBen Crawford, CSCP, Production and Inventory Control Manager, Superior Essex

QAD Explore 2012

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The following is intended to outline QAD’s general product direction. It is intended for information purposes only, and may not be incorporated into any contract. It is not a commitment to deliver any material, code, functional capabilities, and should not be relied upon in making purchasing decisions. The development, release, and timing of any features or functional capabilities described for QAD’s products remains at the sole discretion of QAD.

Safe Harbor Statement


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• The Effective Enterprise• Solution overview• Superior Essex implementation review• Next steps • Vision• Summary • Questions

Presentation Agenda


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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


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• Integrated view of key planning and scheduling data elements

• Ability for quick visibility to:- Supply and demand issues- Machine capacity issues- Material shortages

.. leading to a higher rate of schedule achievement

.. improving delivery schedules

.. helping reduce inventory levels

Effectiveness of Planning and Scheduling Workbenches


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Solution Overview


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Scheduler’s Challenge


Executives

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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Planning and Scheduling Paradigm


POs

Planning

DataForecast

Capacity

WOs

BOMs

Routings

WorkCenters

QOH

Safety StockShop

Calendar

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Common Scheduling Situation


… …

MRP DETAILSRESOURCE LOADWO MAINTENANCEDEMAND DETAILS

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QAD Solution


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MSW – Master Scheduling Workbench


Capacity FrameDisplays capacity information per selected resource in the Schedule Grid- Balance your planned and required capacity.

Schedule GridThe primary context of the workbench. - View and modify your production schedules for each item.

Supply/Demand FrameProvides demand & supply information per selected item in the Schedule Grid.- Primary information used for scheduling decision making.

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MSW – Master Scheduling Workbench


Supporting PanelsEnables master scheduling action and decision making.

Represents over 30 maintenance programs and reports!

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PSW – Production Scheduling Workbench


Production Order Sequence GridSchedule and sequence production orders by item attributes

Production Order BrowseSearch & group data per user specification - Drag & Drop the

orders to the desired position on the Sequence Grid.

Production Order MaintenanceView and maintain all order details

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Solution Components Tied Together


Months-Weeks-Days

Days Day-Shift-Intervals

Master Scheduling

Production Scheduling Release To shop Floor Execution

Master Schedule Workbench (MSW)

Create a master schedule balanced to supply / demand / resources

Maximize production efficiency through schedule optimization

Release to production with verification of

available materials

Production Scheduling Workbench (PSW)

Component Available Check (CAC)

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Recent Enhancements


Product structure filter

EAM integration

Co-\by-product support

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Product Structure Filter

QAD’s Planning and Scheduling Workbenches

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Recent Enhancements



EAM integration


EAM Orders Created

• No WB visualization • No consumption of WB capacity

Maintenance work starts

• No change on WB

EAM Orders Scheduled• Visualization

on WB• No impact to capacity on WB

Order Closed

• Scheduler can see work is complete and see history if desired

EAM Integration


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Recent Enhancements



EAM integration


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Availability and Documentation


Workbenches – general:

• eB2.1 SP4 and up, add-on• 2010.1EE and up, core

Recent enhancements• 2012 EE except for co\by• EE package – target release: May • SE package – target release: JulyDocumentation

• Installation, admin, user and training guides

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Superior Essex Implementation Review


Ben Crawford, CSCP

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• Essex Wire was founded in Detroit, Michigan in 1930; roots based in automotive

• Acquired by Superior Telecom Inc in 1999 to form Superior Essex• Acquired by LS Cable in 2008 based in Seoul, South Korea• Corporate offices located in Atlanta, Georgia• North America Magnet Wire headquartered in Fort Wayne, Indiana• Number #1 Global Magnet Wire• Number #2 North American Magnet Wire• Number #3 Global Wire and Cable• Vertically integrated, producing own enamels and copper rod • Markets: Automotive, Commercial & Residential, Energy, Industrial,

Distribution• Global footprint• Discrete manufacturing• QAD ERP: 2008 SE

Superior Essex Overview

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Superior Essex Production Flow


OvenWire

Drawing

Copper

Rod

Spool

Shipping

Packaging

Enamel

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• Pain Points- No master scheduling process in place- 900 to 4000 SKUs per plant- Stock replenishment system with poor forward

visibility- Limited capacity visibility – spreadsheet system- Homegrown scheduling tools not integrated

with QAD- Schedulers searching multiple tools to gather

information for decision making- Managers needed to query multiple sources to

review results

Challenges


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• After MSW/PSW implementation- Improved customer service- Improved component material purchasing and

forecasting- Increased Scheduler confidence- Greatly improved capacity visibility- Machines grouped by capabilities

Benefits


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Machine Group Setup


MSW SetupPSW Setup

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• Currently live at one location – Feb 2012- Kendallville, IN

• Next plant go live in June- Franklin, IN

• All 6 North American plants scheduled to be live by Jan, 2013

• Locations outside North America to be considered after these 6 are complete

Implementation Plans


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• Familiarize plant with MRP planning reports before go live

• Educate plant on .Net UI before go live• Group like-machines together and tie

items to respective group• Train scheduling team and encourage

MSW/PSW practicing before going live• Data cleanup is critical • Leadership and executive support is key

for success

Lessons Learned


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• Involve other departments- Let workbenches drive involvement

• Start simple• Move to production quickly • Hardly ever an “all or nothing”• Iterative implementation and learning

process

Implementation Considerations


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Next Steps


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Next Steps


2012

May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul201

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Aug Sep

SE Package

- Co-\By-product support- Product Structure Filter- EAM integration- 2012 SE support

SeptemberRelease

- Performance improvements- WO API improvement- Maintenance

- Continuous EE\SE maintenance\enhancement bundle releases- Move co-\by-product functionality into core - Support for new MFG capabilities- MPS leveling- Graphical board metaphor- Operation-based scheduling

Beyond Sept 2012

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Vision


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Vision


Master Schedule

Material Plan

Load-Leveling Constraint-

Based Master Scheduler

Master Scheduling Workbench

Material Requirements

Planning

Production Scheduling Workbench

Finite Capacity Production Scheduler

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MPS Leveling Calculation


Time

Volume Demand Level

Production

Calculates a level loaded (constraint based) Master Production Schedule over a user defined period of time for a site

or group of production lines.

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Vision


Master Schedule

Material Plan

Load-Leveling Constraint-

Based Master Scheduler

Master Scheduling Workbench

Material Requirements

Planning

Production Scheduling Workbench

Finite Capacity Production Scheduler

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Summary


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• Integrated planning and scheduling tool set

• Reduce planning and scheduling time and complexity

• Compress manufacturing response• Provide ability to create effective

plans and schedules• Enable to be proactive

Planning and Scheduling WBs Value


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• Review available documentation - QAD web site: planning and scheduling

workbenches

• Work with QAD services/partner to line up training

• Work with QAD/partner account rep to schedule demo

Next Steps After Explore


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Carianne NieuwstratenProduct Manager, QAD. [email protected]

Ben CrawfordProduction and Inventory Control ManagerSuperior [email protected]

Questions & Answers


qad planning and scheduling workbenches carianne nieuwstraten, product manager, qad. inc ben...

Documents

qad solution qad planning

solution overview qad

superior essex qad

sole discretion of qad

capacity information

delivery schedules

product manager

inventory control manager