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Next Edition for Manufacturing & Supply Chain Enhancing Core Product for Batch-Process Industry. SoCal + Bay Area User Groups Robin Ward Vita Tech Bengt Johansson QAD Supply Chain & Manufacturing March, 2009. Building for. You. Building for You. Minor Releases

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next edition for manufacturing supply chain enhancing core product for batch process industry

Next Edition for Manufacturing & Supply ChainEnhancing Core Product for Batch-Process Industry

SoCal + Bay Area User Groups

Robin Ward

Vita Tech

Bengt Johansson

QAD

Supply Chain & Manufacturing

March, 2009

building for you
Building for You
  • Minor Releases
    • QAD 2009 / 2009.1 / 2010 / 2010.1
    • Standard Edition
    • Enterprise Edition
    • New versions complementary products
  • Next Major Release
    • Codename “Deming” after William Edwards Deming
    • Only Enterprise Edition
    • Planned for 2011
deming release
Deming Release
  • Named after W. Edwards Deming
    • Deming made a significant contribution to Japan\'s later renown for innovative high-quality products and its economic power
  • Planned for 2011
  • Based on Enterprise Edition
  • Main themes:
    • The Perfect Lean Market
    • Further increase the functional depth of QAD Manufacturing
    • Improvements related to the Process Industry
  • Developed in close cooperation with customers
deming manufacturing enhancement areas
Deming Manufacturing Enhancement Areas
  • Perfect Lean Market
    • Expansion of Lean Capabilities
    • Extending the Value Stream Model
    • Total Quality Management in Supply Chain
  • Convergence/Reconciliation/Standardization of Manufacturing solutions
    • Combining strengths of various solution into one elegant Manufacturing framework
  • Enhance the Manufacturing User Experience
    • Simplified Implementation
    • Streamline Operations
    • Decision Support / Role-Based Workbenches
    • Improved Visibility
  • Process Industry Extensions
    • Pharmaceutical/Biotech
    • Food and Beverage
    • Chemical
perfect lean market manufacturing enhancements
Perfect Lean Market - Manufacturing Enhancements
  • MPS Calculation
  • QPS Master Schedule Workbench
  • QPS Production Schedule Workbench
  • Manufacturing Execution – Mixed Mode
  • And much more….
master scheduling calculation
Master Scheduling Calculation
  • Automatic Master Scheduling Calculation
  • Build an 80% accurate MPS
  • Balance Supply / Demand
  • Spread over Production Lines
  • Order Smoothing
  • Line leveling
  • Configurable Rules
qps workbenches
QPS Workbenches
  • QPS Master Scheduling Workbench
  • QPS Production Scheduling Workbench
  • Component Availability Check
  • QPS will be the only tool for production scheduling
slide10

Master Scheduling Workbench

Capacity / Load

Production Plan

Supply / Demand

More Item, Order, Demand info

manufacturing execution mixed mode
Manufacturing Execution - Mixed Mode
  • Basis for MAJOR restructuring of manufacturing
  • Eliminate as many differences as possible between WO and Repetitive
    • WO on Production Line
    • Repetitive picklists on WO
    • WO Issue on Repetitive
    • Common Shopfloor Reporting, Backflushing
    • Repetitive CUM-order for WO
    • Kanban integrated with Repetitive
  • More Flexibility
  • Greater Control
  • Easier to use and implement
  • Lean Principles
slide12

Enhancements

for

Process Manufacturers

commitment to innovation
Commitment to Innovation

QAD Strategic

Steering Committee

QADCustomers

QAD Product

Review Committee

IndustryStandards

VerticalMarket

AnalystsResearch

Industry Roadmap

ProductRoadmap

Product Definition

CompetitiveAnalysis

INSIGHT™

CustomerRequests

QAD Field Feedback

QAD SupportFeedback

QADPRC

CustomerAdvisory Groups

Development Groups

Technical

Foundation

Collaborative Development

listening to you
Listening to You

QAD has been researching Customer Requests coming from visits and

Enhancement Requests reported to us

More then 20 QAD Customers / Partners have been participating in

defining and prioritizing which key features process manufacturers

need to be competitive today and in the future

Based on this feedback project started to increase functional depth of QAD

Supply Chain & Manufacturing capabilities

process manufacturing advisory board
Process Manufacturing Advisory Board

Initial Involvement:

Met April 2008 at QAD Headquarters (10 companies)

QAD Identified Business Requirements

Team Prioritized Deliverables

QAD Created Timeline

Ongoing Conference Calls:

Periodic Conference Calls

Explorer Meetings

slide18

Process... the Final Frontier.

These are the voyages of the star(ship) of

Enterprise Resource Planning (QAD).

Its five-year mission (hopefully less):

to explore strange new worlds (verticals),

to seek out new life (functionality)

and new civilizations (customers),

to boldly go where no

man has gone before.

process manufacturing industries
Process Manufacturing Industries
  • Pharmaceutical & Biotechnology
  • Processed Food & Beverages
  • Chemical Products Industry
  • Consumer Packaged Goods (Personal Care, Tobacco etc.)
  • Other Industrials (Metal, Paper, Recycling,...)
main characteristics
Main Characteristics
  • Variable & Unstable Material Characteristics
  • Amorphous materials
  • Quality Control & Quality Assurance
  • Highly Regulated Industry
  • Formulas or recipes
  • Batch Manufacturing
  • Complex Manufacturing
  • Packaging, Labeling, Picking, Shipments, Transportation – “CPG”
variability ai potency batch balancing
Variability – AI - Potency & Batch Balancing
  • Potency/ Purity / Strength / Concentration Level/ Assay%
  • Formula Definition
  • Formula Adjustments / Batch Balancing

Aspirin (Acetylsalicylic acid)

-A: Salicylic Acid

-E: Sodium

-E: Acetyl Chloride

Spiraea

Ulmaria

instability shelf life based attributes
Instability – Shelf Life-Based Attributes
  • Date Driven Characteristics
  • Quality
  • Health & Safety
  • Planning
  • Logistics
stuff not things multiple uom
“Stuff” not “Things” – Multiple UOM
  • Alternate UOM
  • Dual UOM (Catch Weight)
quality lot classifications lot measurement lot reference
Quality – Lot Classifications, Lot Measurement, Lot Reference
  • Extended Attributes
    • Grade, Color, Grain Size,…
    • pH, Moisture Content, Hardness,…
    • Origin of Goods (Supplier, Country of Origin, Allergen, Chemical Content …
  • Include in processing & validations
quality lot track tracing
Quality - Lot Track & Tracing
  • Item & lot attributes
  • Lot Track & Trace
  • Lot Control
  • Returns & Recalls
batch process manufacturing

Raw

Materials

Bulk

Product

Mixing/

Blending

Batch/Process Manufacturing
  • Recipe-based Production
  • Attribute-based Production
  • Retrieval WO Productivity Data
complex process manufacturing
Complex Process Manufacturing
  • Mixed-Mode Manufacturing
  • WO Stream – Linked multi-stages
  • Co-By-Products & Recycled Goods
  • Flexible Packaging Alternatives
  • Rule-based Formulas/Processes
  • Capacity & availability Tanks & Vessels
  • Quality Assurance/Compliancy Regulations
consumer goods packaging picking shipment
Consumer Goods – Packaging, Picking & Shipment
  • Packaging
    • Packaging BOM
    • Plan & Schedule Packaging
    • Packaging and Labeling
  • Extended attribute-based Picking & Shipping logic
product development plan
Product Development Plan
  • PHASE 1
  • Potency & Batch Balancing
  • Alternate UOM in Supply Chain
  • Recipe-Based Formulas & WO’s
  • WO for Batch-Process Mfg
  • Backward & Forward Lot Traceability
  • PHASE 3
  • Shelf Life Mgmt & Planning
  • Enhancements PCC, QM
  • Enhancements Co/By-Products
  • Packing, Picking & Shipment
  • Integration with MES, LIMS, QMS (Foundations Team)
  • Recall & Returns (TBD with Customer Management-SSM)
  • PHASE 2
  • Dual UOM in Supply Chain
  • Catch Weight (Sell/Ship/Invoice)
  • Enhanced Manufacturing Improvements
  • Supplier Qualification & Origin of Goods
  • Lot Classifications & Planning/WO Execution
  • Configurable/User-definable Attributes
  • PHASE 4
  • Early Adopter/
  • Go-to-Market Preparations

March 2009

September2009

March

2010

September

2010

focused work groups
Focused Work Groups
  • 3 Focus Groups until end-of-2008
    • Potency & Batch Balancing
    • Batch Manufacturing (Improving WO Execution)
    • Lot Traceability (Forward/Backward Lot Traceability)
  • Objectives
    • To fully understand specific requirements, current practices, business scenarios & gaps
    • To help define Use-/Test-cases and set-up test environments
    • To agree on conceptual solution design
    • To help during development process & assist with testing software
  • Current Activities
    • Fully understand impact all business requirements in scope of focused group
    • Work out Business & Test Scenarios
    • Define & agree on conceptual solution designs

Ensure Market Acceptance & Accelerate Product Development

current activities with work groups
Current Activities with Work Groups
  • Work Group 1.1 Potency & Batch Balancing
  • Work Group 1.2 Enhancements in Formulas & Work Orders
  • Work Group 1.3 Improved Lot Traceability Capabilities
wg1 1 potency master data
Item, Item-Site Maintenance

Extended Attributes Enabled

Target Potency

Potency Tolerance

Potency Enforcement

Customer Item, Supplier Item Maintenance

Target Potency

Potency Tolerance

Potency Enforcement

Unit of Measure Master table

Rounding factor

Improved UM Maintenacemfg

Formula Maintenance

Specific Target Potency values

Potency Tolerance

Potency Enforcement

Component Type, Active, Excipient, Standard

WG1.1 - Potency & Master Data
wg1 1 potency material management
WG1.1 - Potency & Material Management
  • Inventory
    • Lot Potency
    • Effective Quantity vs. Physical Quantity
    • Planning and Costing in Effective Quantities
    • Inventory movement in Physical Quantities
  • Inventory Potency Adjustment
    • New Transaction
  • PO Potency aware
    • Target potency
  • PO Receipt
    • Potency enforcement
    • Physical Quantity + Potency
wg1 1 potency wo batch balancing
WG1.1 – Potency & WO Batch Balancing
  • Potency - Planning (MRP), Inventory Valuation
    • Effective Quantities
  • Inventory transaction in Physical Quantities
  • Work Order Batch Balancing
    • Potency enforcement at allocation
    • Single and Multiple Active Ingredients
    • Auto Batch Balancing / WO BOM Adjustments at Work Order Release
    • Manual Batch Balancing on demand
      • Before Release
      • After Release
formula
Formula
  • Batch Total = 1000 Kg
  • Active Total = 180 Kg @ 80%
  • Excipient Total = 175 Kg Ratio: 0.2 | 0.686 | 0.114
planned work order bom
Planned Work Order BOM
  • Batch Total = 3000 Kg
  • Active Total = 540 Kg @ 80% (= 675 Kg Physical)
  • Excipient Total = 525 Kg Ratio: 0.2 | 0.686 | 0.114
work order bom after batch balancing
Work Order BOM after Batch Balancing
  • Batch Total = 3000 Kg
  • Active Total = 540 Kg @ 85% (= 635.59 Kg Physical)
  • Excipient Total = 564.71 Kg Ratio: 0.2 | 0.686 | 0.114
  • Delta = 39.71 Kg less Phys Qty Active / More in Excipients
wg1 2 enhancements in formulas work orders
WG1.2 - Enhancements in Formulas & Work Orders
  • Formulas
    • Scalable/Non-Scalable Component
    • Alternate UM for components
    • Recipe-style Process/Formula Definitions
  • Work Orders
    • Recipe-style Work Order Instructions
    • What-If Analysis
    • Capturing Data in Alternate UM during WO Component Issue / Allocations
    • Enabling Potency & Batch Balancing in al WO Functions
  • Manual WO Component Allocation
    • New Transaction, Similar to SO Manual Allocation
  • WO Productivity Reports
    • WO Variance Reports to analyze Productivity, Utilization & Yield
    • WO BOM “snap-shot” for auditing and “As-Planned” vs “As-Built” analysis
wg1 3 lot trace enhancements
WG1.3 – Lot Trace Enhancements
  • Improve tools for Lot Trace Analysis
    • Backward Lot Traceability
    • Forward Lot Traceability
  • Objective
    • To better fulfill Regulatory Compliancy
    • Decrease time spent in “recall management”
    • Improve operational excellence
slide47

Phase 1 Project Deliveries

        • Potency & Batch Balancing
        • Formula & WO Process Improvements
        • Enhanced Lot Traceability Capabilities
benefits
Benefits
  • Opportunity to have a voice in your industry’s ERP functionality.
  • Educational Experience!
  • Good Opportunity to Network!
  • It’s fun!
next planned activities work groups
Next planned activities Work Groups
  • WG 2.1 – Extended Attributes
  • WG 2.2 – Dual UOM
  • WG 2.3 – Quality
  • WG 2.4 –Next Edition Manufacturing
conclusions
Conclusions
  • QAD invests to enhance its products for Process Manufacturers
  • QAD builds together with YOU
  • We will be ready in March 2011
for more information
For more information
  • Please Contact:
    • Guido Van den Broeck

Product Manager [email protected]

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