QAD Planning and Scheduling Workbenches

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19 Οκτ 2013 (πριν από 3 χρόνια και 7 μήνες)

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QAD Planning and Scheduling Workbenches

Carianne Nieuwstraten
, Product Manager, QAD. Inc

Ben Crawford, CSCP
, Production and Inventory Control Manager,
Superior Essex


QAD Explore 2012


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

QAD Planning and Scheduling Workbenches

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The Effective Enterprise


Solution overview


Superior Essex implementation review


Next steps


Vision


Summary


Questions


Presentation Agenda

QAD Planning and Scheduling Workbenches

3



“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

QAD Planning and Scheduling Workbenches

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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

QAD Planning and Scheduling Workbenches

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Solution Overview

QAD Planning and Scheduling Workbenches

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Scheduler’s Challenge

QAD Planning and Scheduling Workbenches

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!

7

Planning and Scheduling Paradigm

QAD Planning and Scheduling Workbenches

POs

Planning

Data

Forecast

Capacity

WOs

BOMs

Routings

Work

Centers

QOH

Safety
Stock

Shop
Calendar

8

Common Scheduling Situation

QAD Planning and Scheduling Workbenches





MRP DETAILS

RESOURCE LOAD

WO MAINTENANCE

DEMAND DETAILS

9

QAD Solution

QAD Planning and Scheduling Workbenches

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MSW


Master Scheduling Workbench

QAD Planning and Scheduling Workbenches

Capacity Frame

Displays capacity information
per selected resource in the
Schedule Grid

-

Balance your planned and
required capacity.

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
used for scheduling
decision making.

11

MSW


Master Scheduling Workbench

QAD Planning and Scheduling Workbenches

Supporting Panels

Enables master
scheduling action and
decision making.


Represents over 30
maintenance programs
and reports!

12

PSW


Production Scheduling Workbench

QAD Planning and Scheduling Workbenches

Production Order
Sequence Grid

Schedule and sequence
production orders by
item attributes

Production Order
Browse

Search & group data
per user specification

-

Drag
& Drop the
orders to the desired
position on the
Sequence Grid.

Production
Order
Maintenance

View and
maintain all
order details

13

Solution Components Tied Together

QAD Planning and Scheduling Workbenches

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)


14

Recent Enhancements



QAD Planning and Scheduling Workbenches

Product structure filter

EAM integration

Co
-
\
by
-
product support

15

Product Structure Filter

QAD’s Planning and Scheduling Workbenches

16

Recent Enhancements

QAD Planning and Scheduling Workbenches

Product structure filter

EAM integration

Co
-
\
by
-
product support

17

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

QAD Planning and Scheduling Workbenches

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Recent Enhancements

QAD Planning and Scheduling Workbenches

Product structure filter

EAM integration

Co
-
\
by
-
product support

19

Availability and Documentation

QAD Planning and Scheduling Workbenches

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

20

Superior Essex Implementation Review

QAD Planning and Scheduling Workbenches

Ben Crawford, CSCP

21


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

22

Superior Essex Production Flow

QAD Planning and Scheduling Workbenches

Oven

Wire
Drawing

Copper

Rod

Spool

Shipping

Packaging

Enamel

23


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

QAD Planning and Scheduling Workbenches

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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

QAD Planning and Scheduling Workbenches

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Machine Group Setup

QAD Planning and Scheduling Workbenches

MSW Setup

PSW Setup

26


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

QAD Planning and Scheduling Workbenches

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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

QAD Planning and Scheduling Workbenches

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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

QAD Planning and Scheduling Workbenches

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Next Steps

QAD Planning and Scheduling Workbenches

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Next Steps

QAD Planning and Scheduling Workbenches

2012

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Mar

Apr

May

Jun

Jul

2013

Aug

Sep

SE
Package

-

Co
-
\
By
-
product support

-

Product Structure Filter

-

EAM integration

-

2012 SE support

September

Release

-

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

31

Vision

QAD Planning and Scheduling Workbenches

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Vision

QAD Planning and Scheduling Workbenches

Master
Schedule

Material
Plan

Load
-
Leveling
Constraint
-
Based Master
Scheduler

Master
Scheduling
Workbench

Material
Requirements
Planning

Production
Scheduling
Workbench

Finite Capacity
Production
Scheduler

33




MPS Leveling Calculation

QAD Planning and Scheduling Workbenches

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.

34

Vision

QAD Planning and Scheduling Workbenches

Master
Schedule

Material
Plan

Load
-
Leveling
Constraint
-
Based Master
Scheduler

Master
Scheduling
Workbench

Material
Requirements
Planning

Production
Scheduling
Workbench

Finite Capacity
Production
Scheduler

35

Summary

QAD Planning and Scheduling Workbenches

36


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

QAD Planning and Scheduling Workbenches

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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

QAD Planning and Scheduling Workbenches

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Carianne Nieuwstraten

Product Manager, QAD. Inc

czn@qad.com


Ben Crawford

Production and Inventory Control Manager

Superior Essex

ben.crawford@spsx.com


Questions & Answers

QAD Planning and Scheduling Workbenches

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www.qad.com

© QAD Inc 2012

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