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2012 Environmental Solutions Group All Rights Reserved© 1CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
Heil’s Integrated Platforming
Expected Heil Benefits
Hard Savings•20% Productivity Gain•5% Direct Material Savings•25% - 40% Inventory Reduction
Velocity Benefits•30% Lead-time Reduction•50% Reduction Time To Market
Complexity Benefits•28 RCV Models to 6?•1 Control Architecture•40+% Reduction Part Numbers?•Reduced Fixed Costs From Scheduling Procurement Testing NPD Doc control Simplification•Warranty Reduction (?)
+ GUIDED SELLING TO PRECLUDE INCOMING UNFUNDED COMPLEXITY
2012 Environmental Solutions Group All Rights Reserved© 2CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
Original Objectives
Back in April/May 2012 the birth of Project GEM started with the following objectives in mind:– Phase 1: Technical PoC
Validate SAP, JDE, Endeavor Commerce and PTC integrate with each other, while receiving best practices and direction to scope out Phase 2.– Phase 2: HalfPack 28 Yard PoC
Create a limited, but complete process from Pro-E/Configurator through production with a confined option set for the 28 yard HalfPack.– Phase 3: Complete FEL Product family
Create a limited, but complete process from Pro-E/Configurator through production with a confined option set for the 28 yard HalfPack.
2012 Environmental Solutions Group All Rights Reserved© 3CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
Leading Action Items(Conceptual - bypass ECO release process)
Engineering Bill of Material (BOM) Restructure: Break down existing HalfPack 28YD Eject BOM structure into “modules” Eliminate Drop/Add items (require both redesign and restructure) Re-order/reshuffle components based on new restructure modules Create new restructured modules in 3D/ProE Re-order/reshuffle components based on new restructure modules Define an absolute reference point for consistent module orientation and placement (and to set
up for Skeleton model)
JD Edwards (JDE) BOM Restructure: Create BOMs for new restructured modules Eliminate Drop/Add items Replace Phantoms with “Make” where ever applicable Redefine Stocking Type, G/L Class, Line Type Potentially eliminate NRM items
Configure a “Production-grade” Proof of Concept (PoC) Truck Generate PoC Work Order Eliminate Drop/Add Redefine or eliminate Sales Part Numbers (SPNs)
2012 Environmental Solutions Group All Rights Reserved© 4CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
The Original PoC Quote
Non-CUSTOM dealer Commercial FEL Half Pack
28 cubic yard body Mack LEU chassis Mack diesel engine with
Allison transmission Front mounted single pump Optional 24” toolbox and 60
gallon washout tank
2012 Environmental Solutions Group All Rights Reserved© 5CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
The Break-down (PoC Picklist)
As result of joint effort among the Half Pack production line, at least 65 (and counting) standard modules were defined based on floor experience and potential variability of options within each module
Note there are more optional modules than standard modules
For more detail go to PoC Picklist spreadsheet
Poc Picklist
2012 Environmental Solutions Group All Rights Reserved© 6CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
BOM Structure Hierarchy - Today
Refer to 28YD HP Eject BOM spreadsheet
2012 Environmental Solutions Group All Rights Reserved© 7CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
BOM Structure Hierarchy - Tomorrow
Refer to 28YD HP Eject BOM spreadsheet
Advantages versus Today’s BOM Structure:– More flexible (add-on modular approach)
– More accurate “real” cost
– More streamlined work orders
– More effective “real” time
2012 Environmental Solutions Group All Rights Reserved© 8CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
Configuration: Today vs GEM
Account: Dealer / Direct Account: Dealer / Direct 1=SPN
Chassis Make: Mack LEU
Chassis Mack LEU2=Eng Top Level
Arm/loaderArm hydraulicsPump support/drivelineDoor latch kit
Fuel Type: Diesel Fuel Type: DieselChassis Engine: Mack Chassis Engine: MackChassis Transmission: Allison Wtech Chassis Transmission: Allison Wtech
Body: Half Pack 28yd Eject (includes warranty)
SubframeBody sides (LH + RH)Roof weldmentHopper sides (LH + RH)Front headerHopper closureTop doorSide doorPacker panelTailgateTailgate propRoof access ladderBumper under-rideArm cylindersBody weldment (req redesign of bolster covers for other flood light options)Body assemblyHydraulic installationBody valvePacker cylindersFront header screenBody prop installationForksFork cylindersMudflaps frontMudflaps rearCab protectorCab protector extensionShovel rackRemote lubeFire extinguisherSafety triangleBODY-UNDERCOATING-DPDC
Mount Instructions: Factory Mount - Eject
Mounting installationHALF PACK MOUNTDPDC Paint Touch-UPCHASSIS CHECKIN & INSPECTIONRUN TEST FOR HALFPACK
Pump: Front Mnt Vane Pump -E -- DenisonPump installationOil tank assemblySensor oil level pump shut off
Control Kits: Mack LEU, Eject Com Jstick -- Commercial Joystick Controls
Cab control w/o AutoliftCab specific kitCab control bracket
Lighting: Lights LED - Commercial
Application specific kitBody Electrical LEDTailgate ElectricalTailgate electrical turn signalsTop door electricalNational account electricalWork light T/G installationStrobe lightHopper lightOverheight warning lightCamera (see Camera Matrix 800-0460)
Throttle: Throttle Advance - Mack Throttle Advance or Limit Warranty
Paint: Paint Color Eject -- as listed on ColorSmart Brochure
FINISH PAINTTRIM KIT-HALF PACKHP DECAL KITHALFPACK MANUAL KIT
Miscellaneous Options: Tool Box - 24in (Bumper Mnt) TOOL BOX,T/G MNT'D INSTMiscellaneous Options: Washout Tank 60gl Side Mnt -E WASHOUT TANK KIT
14 vs 71 line itemsFor example:1 vs 32 in “Body”
Source: JDE GEM.xlsx
2012 Environmental Solutions Group All Rights Reserved© 9CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
PoC 3D/ProE with Restructured Assembly Tree
Refer to video on exploded FEL Master
2012 Environmental Solutions Group All Rights Reserved© 10CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
Example of What to Restructure:Oil Tank Assembly 020-2474
5 levels deep under SPN
49 line items Eliminate Level
1 Phantom Eliminate NRM 3 new parts and
3 new BOMs (including converting 2 Phantoms)
GEM = 3 levels deep (cf to 6)
2012 Environmental Solutions Group All Rights Reserved© 11CONFIDENTIAL – Do Not Reproduce
COLLABORATIVE ENTREPRENEURIAL SPIRIT WINNING THROUGH CUSTOMERS HIGH ETHICAL STANDARDS, OPENNESS, AND TRUST EXPECTATIONS FOR RESULTS RESPECTS AND VALUES PEOPLE
Moving Target
During project GEM restructuring progress the following events have or will have been taken place:– Product rationalization nullified
– CNG restructured into sub modules in various matrices
– Electrical restructured into modules
– Side Saddle (Streetwise) hydraulics to be implemented• New FEL matrices introduced
– Next generation AFL to be “platformed”
– New modeling and assembly standards to be introduced• Updated start parts with datum nomenclature and layering schemes• ModelCheck to drive model consistency• Skeleton models and Simplified Representations to be created at top level
assemblies
– Platforming Strategies workshop and meetings Essentially a 28YD Half Pack configured today is structured quite differently
compared to the original PoC quote in April/May 2012