Manufacturing Product Strategy and Direction Bengt Johansson, CPIM Product Architect Nicole Groves, CPIM Business Analyst Manufacturing R & D

Manufacturing Product Strategy and Direction

Bengt Johansson , CPIM Product Architect Nicole Groves, CPIM Business Analyst

Manufacturing R & D

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Thank You for Being a QAD Customer!


“The purpose of a company is to create a customer. To satisfy the customer is the mission

and purpose of every business.”

Peter Drucker

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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


QAD Development Roadmap Cycle


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Roadmaps• Vertical Roadmap• Product Roadmap• Product Definition

Industry Trends and Standards• Vertical Standards• Technical Standards

Market Evolution• Industry Analysts• Competitive Analysis• Development Groups• Technology Advances

QAD Customers• Collaborative Development• INSIGHT™• Customer Requests• Customer Advisory Groups• Field & Support Feedback

QAD Strategic Steering Committee

QAD Product Review Committee

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• This Is What You Have Said- Make Better Planning/Scheduling Decisions

• Workbenches

- More Automation for Manufacturing• Manage by Exception

- Extending/Connecting the Enterprise• Integration / Interoperability

- Better Access to Manufacturing Information• Leveraging Mobile Devices

- “Next Level” of Manufacturing (Process and Discrete)

Building to an Effective Enterprise


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• Master Scheduling Workbench (MSW)- Aligns Demand and Supply throughout the

Planning Horizon• Highlights Supply Shortages• Calculates Projected Inventory

- Calculates and Monitors Workload Capacity• Highlights Overloads

- Provides Access to Processes and Information to Put Decisions into Action

• Shows Immediate Effects

Making Better Planning / Scheduling Decisions


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• Production Scheduling Workbench (PSW)- Aligns Demand and Supply throughout the

Scheduling Horizon• Highlights Supply Shortages• Calculates Projected Inventory

- Calculates and Monitors Workload Capacity• Highlights Overloads

- Component Availability Check (CAC)• Checks Material Availability before Committing to

Production

- Provides Access to Processes and Information to Put Decisions into Action

• Sequencing (Drag and Drop)• Shows Immediate Effects

Making Better Planning / Scheduling Decisions


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Increase Your Manufacturing Efficiency with QAD’s Planning and Scheduling Workbenches

Tuesday 8:30 Mediterranean Room

Gary Wasserman – QAD Inc

Learn More!

Planning and Scheduling Workbenches

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• Load-Leveling, Constraint-Based Master Scheduler- Order Smoothing- EPEI- Finite Capacity

• Builds Master Schedule Automatically- Reduces Manual Effort and Time

More Manufacturing Automation


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4 Steps• Demand/Supply Balancing • Production Line Allocation • Order Smoothing • Line Leveling

• Batch or “on demand” MSW• By Item and Production Line Leveling• Sensitive To Type Of Demand Being Satisfied• Sensitive To Order Priority• Re-level and/or view with MSW

Master Scheduling


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Master Scheduling - Planning


DemandSO, DO, Forecast

MPS

Review PlanMSW

MRP

Review MSWRelease PSW

Finite Leveling Engine

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• Periodic Costing- Compliance Issue with (local) Legal Tax

Requirements in Many Countries- Compliance Issue with the IFRS- FiFo, LiFo, Weighted Average Valuation

• PO Re-Pricing- Retroactive

Pricing

More Manufacturing Automation


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• Serialization- Improve Supply Chain Efficiency (Operations)

• Trading Partner Regulations

- Brand/Product Protection and Safety

• Counterfeit Products• Tracking / Tracing

- Compliance Issues

Extending / Connecting the Enterprise


• Define different packaging types

• Define packaging structures

• Assign default packaging structures per item per origin/destination

Packaging Master Data

Serialization Features

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Serialized Inventory Management


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• Serial Master & History Data independent from lot inventory

• Serialized Packaging Hierarchies

• Serialization fully integrated with inventory transactions

• Support of specific packaging transactions

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• Connectivity / Services- Fully Integrated Inventory Transaction APIs- Label / Bar Code Printing



Supplier

Receiving Inventory Production Shipping CustomerPackaging

RF UI / Barcode Data Collection


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• API ready for 3rd party products.- Eagle,- Factivity- Freedom- Radley

• Warehousing RFUI expanded

• Programmatic (Progress)• QDOCs (QXtend)

Label Printing


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• Label formats by Item, Site, Pack, partner

• Printer Definitions• Data to Format Mapping• Print server interface (e.g.

Loftware)• Printing from key transactions• Label Reprint

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• Business Intelligence- Connects People to Data- Analyzes Data and Disseminates Measurement

Information• Provides Visibility to Historical Trends Resulting in

Operational Insight• Supports Better, Faster Business Decision-Making

- Cut Costs- Identify Opportunities

Better Manufacturing Information Access


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Available now• Purchasing• Inventory

March 2012• Manufacturing

Business Intelligence

Effective Enterprise - Manufacturing

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Business Intelligence - Dashboard


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Process Industry Projects• Configured Attributes• Quality Extensions• Potency and Concentration

- For Early Adopters

Manufacturing to the Next Level


• Challenges: - Disparate and variable Item characteristics- Ever changing regulations- Capture Item/Lot Information at transaction

processing

• QAD Solution- Flexible definition descriptive attributes- Enable attributes by function- Fully Integrated to Core Operation

Configurable Attributes


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InventoryManagement

Lot Master with Attributes

Inventory with Attributes

Certificationwith Attributes

Item ProfileAttribute

SpecificationsBusiness Order

Attribute Specifications

Transaction Historywith Attributes

Purchasing

Production

Sales and Fulfillment

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ColorDiameterFiber ContentTransportation

RequirementEthanol%KosherHazardous ClassUL Listingppm granularsCE CertificationProcess TemperatureRoyalty CostClarityTrans Fat ContentRatingBest Before DateOrganicOrigin RoHS CompliancypHNutritional ContentPurity%



InventoryManagement








Purchasing

Production


Define Item Attributes Default valueSpecifications and tolerancesValidationsSupplier Item, Customer Item

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InventoryManagement








Purchasing

Production


Optionally specify business order specifications Override specificationValidated with inventory transactions

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InventoryManagement








Purchasing

Production


Business transactionsQuality OrdersCapture valuesValidate specificationsKeep history

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InventoryManagement








Purchasing

Production


Material CertificationsItem attributesLot attributesPrintable document

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• Quality Extensions- Establish Improvements in Quality

Management Through Inspection Result Processing

• Document Quality Test Results - Associated with Attribute Values- Multiple test results

• Consistent Product Specifications• Quality Criteria and Supplier Certification• Supplier Performance

- Product Traceability• Backward / Forward



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Quality Extensions


InventoryManagement

QualityManagement

Item and Test Cross Reference

Testswith Attributes

and Specifications

Purchasing

Production

TestSample Unit

Results

Test Sample Results

Test Results

Quality OrderResults

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Quality Extensions


InventoryManagement

QualityManagement



and Specifications

Purchasing

Production

TestSample Unit

Results

Test Sample Results

Test Results


Define tests with attribute specifications•Target value•Specifications •Tolerances•Capture results at

• Test• Test sample• Test sample unit

•Apply to Certification Records

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Quality Extensions


InventoryManagement

QualityManagement



and Specifications

Purchasing

Production

TestSample Unit

Results

Test Sample Results

Test Results


Define Item Testing•Assemble test sequences•Pass/Fail•Observation

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Quality Extensions


InventoryManagement

QualityManagement



and Specifications

Purchasing

Production

Test Sample Unit Results

Test Sample Results

Test Results

Quality OrderResultsQuality Orders

•Results with every detail•Linked to original document•Inventory Lot•Certification

•APIs for data collection

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Lot Trace – Backward (Supplier Data)


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Lot Trace – Forward (Customer Data)


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• Mixed Mode Manufacturing Environments- Single Solution Design- Integrated Features- Consolidated

• Business Processes• Consistent UI



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• Hybrid Mode- Batch/Process

• Mixed Mode- Work Orders- Repetitive- Flow

• Lean/Kanban

Mixed Factory Environments


One Factory One System Hybrid Mode Mixed Mode

Production Orders – The Next Level

Freeze BOM / Routing

Scrap

Backflush

Receive FG

Close Order

Production Accounting

AllocateMaterial

Print Picklist

Issue MaterialTransferMaterial

Release Order

ComponentAvailability

Check

PlanningScheduling

Produce

Print ShopPapers

ReportLabor

SubcontractProcessing

BatchBalancing


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• MRP/Gross Requirements Calculation- Material Planning for Lean Production

Environments (Pull Systems)• Provide forecasts to suppliers for mid/long term• Capacity planning for kanban production

- Component Demand • Average Demand Calculation• Kanban Sizing and Kanban Workbenches

- Process- Loop

• Mid and Long Term Material plans for suppliers and subcontractors



• Plans order release date for gross requirement

MRP /Gross Requirements Calculation


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Requirement Due Date

Planned Order Due Date

Planned Order Release Date

Inventory Shipping

Conventional MRP plans orders with due dates to satisfy the requirement due date

Order Policy: POQ, FOQ, LFL

Supply inventory to be consumed by

the requirement.

Backward Scheduling

Requirement Due Date

Inventory Shipping

MRP with gross requirements calculation plans order release dates based on the projected consumption of inventory using the requirement due date

Order Policy: GRC

Signal Replenishment for inventory consumed

by the requirement.

Planned Order Due Date

Planned Order Release Date

Forward Scheduling

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• Kanban Sizing Workbenches

Lean – Continual Improvement


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• Lean Transactions- Cumulative Orders- Accountability- Improved Integration (Closed Loop)

• Move Loop Modeling - Model flow of material from Supermarkets to

a customer, subcontractor, warehouse or process.

• Dispatching- Calculate Dock Dates- Create Supplier Shipping Schedules- Dispatch to subcontractors



Subcontract and Supply – The Next Level

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Promote the efficient and uninterrupted flow of materials to subcontractors

Provide schedules to subcontractors to manage limited warehouse space

Support high volume of shipments and materials to multiple subcontractors

Provide financial accounting for materials


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• Subcontract Supply Subsystem- Manage Subcontract Supply based on

subcontract schedules- Automatic creation of supply orders based on

BOM• Supplied WIP Items• Raw Materials

- Plan Components for Outbound Shipment• Pick / Ship (Sub-Location)• Ownership Accountability• Subcontractor Sends Kanbans

- Drop Ships



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Building to an Effective Enterprise : Summary


Enhancement AutomotiveConsumer Products

Food and Beverage

High Technology

Industrial Manufacturing

Life Sciences

Periodic Costing H H H H H H

Information Requirements H H H H H H

Business Intelligence H H H H H H

MSW/PSW H H H H H H

Kanban Workbenches H H L H H H/L

Extended Attributes H H H H H H

Serialization H H H H H H

Quality Extensions H H H H H H

Connectivity / Services H H H H H H

Constraint-Based MS H H H H H H

Lean Material Planning / Extensions H H L H H H/L

Subcontract Manufacturing H H M/L H H M/L

Retro-Pricing H M M M H L

Questions


www.qad.com

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Bengt Johansson, CPIM

[email protected]

Nicole Groves, CPIM

[email protected]© QAD Inc

For More Information, Please Contact


http://www.qad.com/

http://www.qad.com/

http://www.qad.com/

http://www.qad.com/

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Documents

Manufacturing Product Strategy and Direction Bengt Johansson, CPIM Product Architect Nicole Groves, CPIM Business Analyst Manufacturing R & D