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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 l.jpg

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


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Building for

You


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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


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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


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It is all for

You


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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


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Perfect Lean Market - Manufacturing Enhancements

  • MPS Calculation

  • QPS Master Schedule Workbench

  • QPS Production Schedule Workbench

  • Manufacturing Execution – Mixed Mode

  • And much more….


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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


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QPS Workbenches

  • QPS Master Scheduling Workbench

  • QPS Production Scheduling Workbench

  • Component Availability Check

  • QPS will be the only tool for production scheduling


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Master Scheduling Workbench

Capacity / Load

Production Plan

Supply / Demand

More Item, Order, Demand info


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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


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Enhancements

for

Process Manufacturers


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Listening to

You


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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


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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


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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


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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.


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Process Manufacturing Industries

  • Pharmaceutical & Biotechnology

  • Processed Food & Beverages

  • Chemical Products Industry

  • Consumer Packaged Goods (Personal Care, Tobacco etc.)

  • Other Industrials (Metal, Paper, Recycling,...)


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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”


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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


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Instability – Shelf Life-Based Attributes

  • Date Driven Characteristics

  • Quality

  • Health & Safety

  • Planning

  • Logistics


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“Stuff” not “Things” – Multiple UOM

  • Alternate UOM

  • Dual UOM (Catch Weight)


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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


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Quality - Lot Track & Tracing

  • Item & lot attributes

  • Lot Track & Trace

  • Lot Control

  • Returns & Recalls


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Raw

Materials

Bulk

Product

Mixing/

Blending

Batch/Process Manufacturing

  • Recipe-based Production

  • Attribute-based Production

  • Retrieval WO Productivity Data


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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


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Consumer Goods – Packaging, Picking & Shipment

  • Packaging

    • Packaging BOM

    • Plan & Schedule Packaging

    • Packaging and Labeling

  • Extended attribute-based Picking & Shipping logic


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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


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Working together with

You


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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


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Current Activities with Work Groups

  • Work Group 1.1Potency & Batch Balancing

  • Work Group 1.2Enhancements in Formulas & Work Orders

  • Work Group 1.3Improved Lot Traceability Capabilities


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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


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Master Data - Items


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Unit of Measure


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Master Data - Formula


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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


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Purchase Orders Receipts


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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


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Formula

  • Batch Total = 1000 Kg

  • Active Total = 180 Kg @ 80%

  • Excipient Total= 175 KgRatio:0.2 | 0.686 | 0.114


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Planned Work Order BOM

  • Batch Total = 3000 Kg

  • Active Total = 540 Kg @ 80% (= 675 Kg Physical)

  • Excipient Total= 525 KgRatio:0.2 | 0.686 | 0.114


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Work Order BOM after Batch Balancing

  • Batch Total = 3000 Kg

  • Active Total = 540 Kg @ 85% (= 635.59 Kg Physical)

  • Excipient Total= 564.71 KgRatio:0.2 | 0.686 | 0.114

  • Delta= 39.71 Kg less Phys Qty Active / More in Excipients


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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


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WO Manual Allocations


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WO Detail Browse


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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


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  • Phase 1 Project Deliveries

    • Potency & Batch Balancing

    • Formula & WO Process Improvements

    • Enhanced Lot Traceability Capabilities


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Benefits

  • Opportunity to have a voice in your industry’s ERP functionality.

  • Educational Experience!

  • Good Opportunity to Network!

  • It’s fun!


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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


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Conclusions

  • QAD invests to enhance its products for Process Manufacturers

  • QAD builds together with YOU

  • We will be ready in March 2011


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It is all about

You


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For more information

  • Please Contact:

    • Guido Van den Broeck

      Product [email protected]

    • Bengt JohanssonProduct [email protected]


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thank you


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