Vision QAD Planning and Scheduling Workbenches

Report
QAD Explore 2012
QAD Planning and Scheduling Workbenches
Carianne Nieuwstraten, Product Manager, QAD. Inc
Ben Crawford, CSCP, Production and Inventory Control Manager,
Superior Essex
QAD Planning and Scheduling Workbenches
Safe Harbor Statement
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.
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QAD Planning and Scheduling Workbenches
Presentation Agenda
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The Effective Enterprise
Solution overview
Superior Essex implementation review
Next steps
Vision
Summary
Questions
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QAD Planning and Scheduling Workbenches
Effective Enterprise
“An Effective Enterprise is one where every
business process is working at peak
efficiency and perfectly aligned to the
company’s strategic goals. ”
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QAD Planning and Scheduling Workbenches
Effectiveness of Planning and Scheduling
Workbenches
• 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
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QAD Planning and Scheduling Workbenches
Solution Overview
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QAD Planning and Scheduling Workbenches
Scheduler’s Challenge
Executives
Finance
ROI must improve;
the stockholders
are not happy!
There’s too
much cash tied
up in inventory!
Manufacturing
Engineering
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!
There’s a new
product
introduction
scheduled for the
fall! But we need
more time for
design!
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QAD Planning and Scheduling Workbenches
Planning and Scheduling Paradigm
POs
Planning
Data
Forecast
BOMs
WOs
Routings
Work
Centers
QOH
Capacity
Shop
Calendar
Safety
Stock
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QAD Planning and Scheduling Workbenches
Common Scheduling Situation
RESOURCE LOAD
WO MAINTENANCE
MRP DETAILS
DEMAND DETAILS
…
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QAD Planning and Scheduling Workbenches
QAD Solution
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QAD Planning and Scheduling Workbenches
MSW – Master Scheduling Workbench
Schedule Grid
The primary context of
the workbench.
- View and modify your
production schedules
for each item.
Supply/Demand
Frame
Provides demand &
supply information per
selected item in the
Schedule Grid.
- Primary information
Capacity
Frame
used
for scheduling
Displaysdecision
capacitymaking.
information
per selected resource in the
Schedule Grid
- Balance your planned and
required capacity.
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QAD Planning and Scheduling Workbenches
MSW – Master Scheduling Workbench
Supporting Panels
Enables master
scheduling action and
decision making.
Represents over 30
maintenance programs
and reports!
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QAD Planning and Scheduling Workbenches
PSW – Production Scheduling Workbench
Production Order
Browse
Search & group data
per user specification
- Drag & Drop the
orders to the desired
position on the
Sequence Grid.
Production Order
Sequence Grid
Schedule and sequence
production orders by
item attributes
Production
Order
Maintenance
View and
maintain all
order details
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QAD Planning and Scheduling Workbenches
Solution Components Tied Together
Months-Weeks-Days
Days
Master Scheduling
Day-Shift-Intervals
Production Scheduling
Release To shop Floor
Execution
Master Schedule Workbench (MSW)
Production Scheduling Workbench (PSW)
Component Available Check (CAC)
Create a master
schedule balanced
to supply / demand
/ resources
Maximize production
efficiency through
schedule optimization
Release to
production with
verification of
available materials
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QAD Planning and Scheduling Workbenches
Recent Enhancements
Product structure filter
EAM integration
Co-\by-product support
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QAD’s Planning and Scheduling Workbenches
Product Structure Filter
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QAD Planning and Scheduling Workbenches
Recent Enhancements
Product structure filter
EAM integration
Co-\by-product support
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QAD Planning and Scheduling Workbenches
EAM Integration
EAM Orders
Maintenance
Order
EAM Orders
Scheduled
work starts
Closed
Created
• Visualization on
• No WB
• Scheduler can
• No
WB
visualization
change onsee work is
• No impact to
• No consumption
complete and see
WB
of WB capacitycapacity on WB
history if desired
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QAD Planning and Scheduling Workbenches
Recent Enhancements
Product structure filter
EAM integration
Co-\by-product support
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QAD Planning and Scheduling Workbenches
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: July
Documentation
• Installation, admin, user and training guides
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QAD Planning and Scheduling Workbenches
Superior Essex Implementation Review
Ben Crawford, CSCP
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Superior Essex Overview
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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
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QAD Planning and Scheduling Workbenches
Superior Essex Production Flow
Enamel
Copper
Rod
Wire
Drawing
Oven
Spool
Shipping
Packaging
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QAD Planning and Scheduling Workbenches
Challenges
• 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
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QAD Planning and Scheduling Workbenches
Benefits
• After MSW/PSW implementation
- Improved customer service
- Improved component material purchasing and
forecasting
- Increased Scheduler confidence
- Greatly improved capacity visibility
- Machines grouped by capabilities
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QAD Planning and Scheduling Workbenches
Machine Group Setup
MSW Setup
PSW Setup
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QAD Planning and Scheduling Workbenches
Implementation Plans
• 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
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QAD Planning and Scheduling Workbenches
Lessons Learned
• 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
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QAD Planning and Scheduling Workbenches
Implementation Considerations
• Involve other departments
- Let workbenches drive involvement
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Start simple
Move to production quickly
Hardly ever an “all or nothing”
Iterative implementation and learning
process
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QAD Planning and Scheduling Workbenches
Next Steps
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QAD Planning and Scheduling Workbenches
Next Steps
SE
Package
September
Release
Beyond Sept 2012
- Co-\By-product support
- Product Structure Filter
- EAM integration
- 2012 SE support
- 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
- Performance improvements
- WO API improvement
- Maintenance
May
2012
Jun
Jul
Aug
Sep
Oct
Nov
Dec
Jan
Feb
Mar
Apr
May
Jun
Jul
Aug
Sep
2013
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QAD Planning and Scheduling Workbenches
Vision
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QAD Planning and Scheduling Workbenches
Vision
Load-Leveling
ConstraintBased Master
Scheduler
Material
Plan
Finite Capacity
Production
Scheduler
Material
Requirements
Planning
Master
Scheduling
Workbench
Master
Schedule
Production
Scheduling
Workbench
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QAD Planning and Scheduling Workbenches
MPS Leveling Calculation
Calculates a level loaded (constraint based)
Master Production Schedule over a user defined
period of time for a site or group of production
lines.
Volume
Demand
Level Production
Time
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QAD Planning and Scheduling Workbenches
Vision
Load-Leveling
ConstraintBased Master
Scheduler
Material
Plan
Finite Capacity
Production
Scheduler
Material
Requirements
Planning
Master
Scheduling
Workbench
Master
Schedule
Production
Scheduling
Workbench
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QAD Planning and Scheduling Workbenches
Summary
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QAD Planning and Scheduling Workbenches
Planning and Scheduling WBs Value
• 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
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QAD Planning and Scheduling Workbenches
Next Steps After Explore
• 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
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QAD Planning and Scheduling Workbenches
Questions & Answers
Carianne Nieuwstraten
Product Manager, QAD. Inc
[email protected]
Ben Crawford
Production and Inventory Control Manager
Superior Essex
[email protected]
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www.qad.com
© QAD Inc 2012
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