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QAD Manufacturing Product Strategy and Direction. Nicole Groves, Sr Staff Business Analyst, QAD Hank Canitz, Sr. Director Industry Marketing - QAD. Agenda. Manufacturing - Roll out plan 2010 Deliverables Process Manufacturing Beyond 2010 Our Vision. Manufacturing 2010 and Beyond.

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Qad manufacturing product strategy and direction

QAD Manufacturing Product Strategy and Direction

Nicole Groves, Sr Staff Business Analyst, QAD

Hank Canitz, Sr. Director Industry Marketing - QAD


Agenda
Agenda

Manufacturing - Roll out plan

  • 2010 Deliverables

  • Process Manufacturing

  • Beyond 2010

  • Our Vision


Manufacturing 2010 and beyond
Manufacturing 2010 and Beyond

  • Internationalization Support- Periodic Costing

  • Workbenches - MSW, PSW, Kanban Sizing

  • Inbound Logistics Accounting

  • Process Manufacturing

  • Integrated Mixed Mode Manufacturing

  • Subcontract Orders and Supply

  • Lean and Kanban Enhancements


High level development plan
High Level Development Plan

March

2010

Jun

2010

Sept

2011

Kanban Wkbch

Production Orders

Master Sched

Wkbch (MSW)

Subcontract Processing

Production Sched

Wkbch (PSW)

Kanban Enhancements

Logistic Accting

Periodic Costing

Process Phase 1

Process Phase 2

Process Phase 3.2 – 3.4

Process Phase 3.1

2010

2012

2011

4



2010 deliverables
2010 Deliverables

  • 2010 EE – March, 2010

    • Periodic Costing - Limited Availability

      • International Requirement

      • Compliance with legal tax requirements & IFRS

      • Actual cost evaluation methods:

        • WAVG

        • FIFO

        • LIFO

          General Availability – September 2010


2010 deliverables1
2010 Deliverables

  • 2010 EE – March, 2010

    • Periodic Costing - Limited Availability

      • International Requirement

      • Compliance with legal tax requirements & IFRS

      • Actual cost evaluation methods:

        • WAVG

        • FIFO

        • LIFO

          General Availability – September 2010

    • Workbenches

      • Kanban Sizing Workbench

      • Kanban Process Workbench

        2010 SE – June 2010



2010 deliverables2
2010 Deliverables

  • 2010 SE – June, 2010

    • Workbenches

      • Master Scheduling Workbench (MSW)

      • Production Scheduling Workbench (PSW)

        • Component Availability Check (CAC) Integration

          2010.1 EE- September, 2010


Planning scheduling future flow
Planning & Scheduling – Future Flow

Period - > Month - > Week - > Day - > Shift - > Interval - > hour

Base

PSW

MSW

MSW

Base

CAC

Production Planned

Production Dispatched

Demand received

Production Scheduled

Production Reported

  • Production Dispatched (PSW)

  • Multi-Select

  • Auto Release

  • Export Dispatch List To Excel

  • (MSW)

  • Export Schedule To Excel

  • Production Dispatched (Base)

  • Integrated Component Availability Check

  • Integrated Single & Multi WO Print

  • View only security for shop floor personnel

  • Production Reported (Base)

  • Monitor WIP of production order

  • Monitor WIP of operations

  • Monitor WIP of production cum

  • Production Reported (PSW)

  • (MSW)

  • Monitor activity with visual completion indicators

  • Production Planned (MSW)

  • Capacity & Load Planning

  • Manage Scheduling Horizon

  • Apply Data Groupings/Filters

  • Select Views (daily-weekly-monthly)

  • Apply Totaling (KYB)

  • Apply Leveling (KYB)

  • Production Planned (Base)

  • Auto-Firm

  • Manage Production Order

    • Header Attributes

    • Operation Attributes

    • Date & Times

Many new capabilities + 60> reports, inquiries, maintenance and process programs rolled up into the new Production Scheduler

  • Demand Received (MSW)

  • Exception Based Visual Indicators

  • Filtering by Exceptions

  • Control Content - Demand/Supply

  • Control Demand Sources

  • Demand Received (Base)

  • Integrated CRP calculates operation dates

  • Demand Detail Drilldown

  • Monitor Inventory


MSW Overview

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.


Demand Details Tab

Provides information related to item demand such as customer and order number information.

MSW Overview

Select Item in Schedule Grid


Psw overview

Production Order Browse

Locate un-sequenced production orders by attributes (red/yellow) (large/small).

PSW Overview

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

Production Order Sequence Grid

Schedule and sequence production orders by item attributes.

Create a schedule by (release date, shift, sequence)

Supporting Tabs


Psw with cac integration
PSW With CAC Integration

Order Component Status

Before releasing to shop floor, verify all component are available.

Order Component (BOM) Frame

Identify the components with shortages, scheduled receipts, partial issues.

Select a component and drill down further into MRP and Inventory Details


2010 planned deliverables
2010 Planned Deliverables

2010.1 EE – September, 2010

Inbound Logistics Accounting

Average Costing compatibility

New manual option to enter logistics charge amounts when creating orders/shippers

New calculation methods


2010 planned deliverables1
2010 Planned Deliverables

2010.1 EE – September, 2010

Inbound Logistics Accounting

Average Costing compatibility

New manual option to enter logistics charge amounts when creating orders/shippers

New calculation methods

Process Industry Enhancements


Process manufacturing enhancement project update

Process ManufacturingEnhancement Project Update

Hank Canitz

Sr. Director Industry Marketing - QAD

Process ManufacturingEnhancement Project Update


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,...)

18


Main characteristics
Main Characteristics

Variable & Unstable Material Characteristics

Formulas or recipes

Complex Manufacturing

Batch Manufacturing

Highly Regulated Industry

Quality Control & Quality Assurance

Packaging, Labeling, Picking, Shipments, Transportation – “CPG”

19


Process manufacturing advisory board
Process Manufacturing Advisory Board

Continuing Efforts:

Ongoing Conference calls

Phase I Solution Testing

Phase II Requirements Definition

Accomplishments:

Phase I Delivered for Early Adopters

Team Prioritized Deliverables

QAD Created Timeline

  • Currently 18 QAD customers are collaborating

    • 9 Pharmaceuticals & Biotech

    • 7 Food & Beverage

    • 2 Chemical Industry

20


Process manufacturers advisory board
Process Manufacturers Advisory Board

Main Goals

Obtaining input from the customer-base

Leveraging industry expertise and day-to-day knowledge

Establishing process for defining and validating common requirements

Improving quality and market acceptance of QAD’s future products & services

Improve Time to Market through joint efforts

Reducing customization & expanding QAD footprint

Main Activities

Understanding main pain points

Documenting key business requirements

Determining highest priority business requirements

Establishing working groups for each development phase

Testing and adopting new functionality


Process manufacturers advisory board1
Process Manufacturers Advisory Board

Value Proposition for PMAB members

Influence and help determine QAD’s future products & services for your industry

Have direct access to product managers and QAD’s R&D Team

Get new solutions up-front (Early Adopter Installation)

Network with affiliated companies and learn from each other

QAD’s expected engagement of PMAB members

Share your valuable time and domain expertise

Be on or plan to be on a recent release of QAD Enterprise Applications

Commitment to implement new functionality and provide feedback

Willingness to be a reference for new developed products



Development plan
Development Plan

May

2010

Nov

2010

March

2011

  • 1.1 PHASE 1

  • Formulas & Work Orders

  • Potency & Batch Balancing

  • 3.3 PHASE 3

  • Complex Mfg

  • 2.3 PHASE 2

  • Integration QMS

  • 1.2 PHASE 1

  • Lot Traceability

  • Enhancements

  • 3.4 PHASE 3

  • Formulas/Formulations

  • 3.2 PHASE 2

  • Attributes (2)

  • 2.1 PHASE 2

  • Attributes (1)

  • Quality

  • 2.2 PHASE 2

  • Catch Weight/

  • Dual UOM

  • 3.1 PHASE 3

  • Packaging, Labels

  • Serialization

QAD EE

2010.1

QAD EE

2011

QAD EE

2012

March

2010

September

2011

September

2009

September

2010

March

2011

March

2012

24


1 1 phase 1 potency batch balancing
1.1 Phase 1 – Potency & Batch Balancing

Aspirin (Acetylsalicylic acid)

-A: Salicylic Acid

-E: Sodium

-E: Acetyl Chloride

  • Potency

    • Standard potency & tolerance ranges at item, item-site & supplier-Item Level

    • Lot potency for Inbound receipts, inventory & work orders

  • Batch Balancing

    • Automatic adjustments of WO BOM based on standard formulas and actual lot potencies of assigned materials following well-determined batch balancing rules

    • Option to re-balance batches manually any time after changes in allocated materials

  • Formula Management

    • Component categories to differentiate types of ingredients/components to be used

    • Standard formulas, with formula-specific standard potency & tolerance ranges

    • Alternate units of measure to define component quantities

    • Non-Scalable component capabilities

  • Work Orders

    • Printing of recipe documents

    • WO manual allocations

25


1 2 phase 1 lot track trace enhancements
1.2 Phase 1 – Lot Track & Trace Enhancements

  • Lot Trace

    • Improved backward & forward lot traceability reporting

    • Lot management (lots / sub-lots)

      • Centralized lot attributes

      • Validations on lot attributes

26


2 1 phase 2 quality attributes
2.1 Phase 2 – Quality & Attributes

  • Extended Attributes

    • Enabling additional item & lot attributes

      • Retest date, use by date, available from date,

      • Supplier lot, origin of goods,..

    • Configurable / User-definable attributes

      • pH, moisture content, specific gravity, color, ...

  • Quality Enhancements

    • Supplier qualification

    • Enhancements regarding receipts & inspections

    • Additional validations during inventory transactions

    • Enhancements to inspections capabilities

27


2 2 phase 2 dual uom catch weight
2.2 Phase 2 – Dual UOM / Catch Weight

  • Unit of Measures

    • Alternate UOM & Rounding calculations

      • Inventory, formulas & work orders

    • Dual UOM / Catch Weight

      • Capture and track inventory in two units of measure

      • Value, order, price, ship, invoice, plan, allocate, produce, by catch-weight UOM & logistics UOM

28


2 3 phase 2 integration qms
2.3 Phase 2 – Integration QMS

  • Quality (2)

    • Integration with QMS (Cebos)

29


3 1 phase 3 packaging serialization label prints
3.1 Phase 3 - Packaging/Serialization/Label Prints

  • Packaging, Labels, Serialization

    • Multiple Packaging Options & Packaging Sizes

    • Labels & required attributes

    • Serialized Packaging

30


3 2 phase 3 extend functionality attributes
3.2 Phase 3 – Extend functionality Attributes

  • Extended Attributes (2)

    • Lot Date Attributes & Business Logic in Planning & Order Promising

    • Lot Assay & Measurable Attributes – Additional Validations / Automatic Calculations

    • Carrying forward material-specific attributes to end-product

    • Flexible picking logics based on additional lot attributes

    • Addl shipping validations based on customer-based criteria

31


3 3 phase 3 enhancements for complex mfg
3.3 Phase 3 – Enhancements for Complex Mfg

  • Complex Manufacturing

    • Mixed-Mode / Hybrid-Mode Manufacturing

    • Co/By-Products

    • Multi-Stage Formula Defitions and WO Routings

32


3 4 phase 3 formulas formulations
3.4 Phase 3 – Formulas / Formulations

Raw

Materials

Bulk

Product

Mixing/

Blending

  • Formulas/ Formulations

    • Recipe-based formulas using full .netUI capabilities

    • Rule-based formulas & work order processing

    • Formula configurations

33



Master data item maintenance
Master Data – Item Maintenance

  • Customer Item, Supplier Item Maintenance

  • Target Potency

  • Potency Tolerance

  • Potency Enforcement

  • Item, Item-Site Maintenance

  • Extended Attributes

  • Target Potency

  • Potency Tolerance

  • Potency Enforcement

35


Master data formula maintenance
Master Data – Formula Maintenance

  • Specific Target Potency values

  • Potency Tolerance

  • Potency Enforcement

  • Component Type: Active, Excipient, Standard

36


Lot potency purchase orders receipts
Lot Potency - Purchase Orders Receipts

  • PO Receipt

    • Target potency

    • Potency enforcement

    • Physical Quantity + Potency

  • Inventory

    • Lot Potency

    • Effective Quantity vs. Physical Quantity

    • Planning and Costing in Effective Quantities

    • Inventory movement in Physical Quantities

37




Development plan1
Development Plan

May

2010

Nov

2010

March

2011

  • 1.1 PHASE 1

  • Formulas & Work Orders

  • Potency & Batch Balancing

  • 3.3 PHASE 3

  • Complex Mfg

  • 2.3 PHASE 2

  • Integration QMS

  • 1.2 PHASE 1

  • Lot Traceability

  • Enhancements

  • 3.4 PHASE 3

  • Formulas/Formulations

  • 3.2 PHASE 2

  • Attributes (2)

  • 2.1 PHASE 2

  • Attributes (1)

  • Quality

  • 2.2 PHASE 2

  • Catch Weight/

  • Dual UOM

  • 3.1 PHASE 3

  • Packaging, Labels

  • Serialization

QAD EE

2010.1

QAD EE

2011

QAD EE

2012

March

2010

September

2011

September

2009

September

2010

March

2011

March

2012

40


Summary
Summary

  • Need more customer participation in PMAB

  • Looking for early adopters

    • Now: Phase 1.1 (Formulas, Potency & Batch Balancing)

    • June 2010: Phase 1.2 (Lot Traceability)

    • Jan 2011: Phase 2.1/3.1 (Catch-Weight and Packaging & Serialization)

41



Beyond 2010 mfg product themes
Beyond 2010 MFG Product Themes

  • Modernization

    • Technologies (.Net, Reporting Framework)

    • Functional/Tool Expansion

  • Convergence/Reconciliation

    • Elimination of Duplication

    • Integration/Interoperability

  • Business Process Re-Engineering

    • Simplification

    • Usability

    • Redesign


Beyond 2010
Beyond 2010

  • Planning/Scheduling

    • Master Schedule Leveling

    • Gross Requirements Calculator


Planning scheduling process flow
Planning/Scheduling Process Flow

Demand Mgmt

S&OP

OrderEntry

90% MPS

Forecasts

Production Plan

Customer Orders

Review / Adjust Master Schedule

MSW/CAC

Constrained Leveling

(MPS Calc)

Master Schedule

Review / Adjust Production Schedule

PSW/CAC

MRP

Subassemblies

Purchased Items

Authorized Production

Procurement

Manufacturing Execution


Planning scheduling process flow kanban
Planning/Scheduling Process Flow - Kanban

MRP/GRC

HistoricalUsage

Master Schedule

Gross Requirements

Average Demand, Safety StockCalc

Average Demand

Kanban Workbench(Sizing)

Kanban SizingCalc

Manufacturing Execution

Kanban Cards


Beyond 20101
Beyond 2010

  • Manufacturing Execution

    • PSW

    • Production Orders ( Redesign of WOs and Repetitive Schedules)

    • Subcontract enhancements

    • Kanban enhancements


Manufacturing execution redesign
Manufacturing Execution - Redesign

  • Production Orders

    • Discrete vs. Schedule

  • Material Management

    • Allocations, Picklists, Batch Balancing

    • Issue Policy, Issue, Transfer, Expense

  • Shop Floor Transactions

    • Common set for Discrete and Schedule

    • Sequencing



Manufacturing execution beyond 2010

Component

Availability

Check

Manufacturing Execution – Beyond 2010

Planning

Scheduling

Report

Labor

Freeze BOM /

Routing

Scrap

Batch

Balancing

Allocate

Material

Print Picklist

Close Order

Backflush

Produce

Subcontract

Processing

Transfer

Material

Issue Material

Production

Accounting

Print Shop

Papers

Receive FG

Release Order


Production orders
Production Orders

  • Discrete (WO) vs. Repetitive - Flow

  • Schedule WO on Production Line

  • Split – Discrete Schedule + Discrete CUM

    • Split Processing – Single Accounting

    • Same BOM/Routing

  • Sequencing

  • Qty to start – Qty to Complete – Expected Scrap

  • Assign Primary Production Line

  • Order Statuses, Discrete + Repetitive

    • Firm, Exploded, Allocated, Released,

  • Co/By Products Repetitive

    • Left-Right production

    • Injection molding



Material management
Material Management

  • Allocations

  • Reserved & Backflush Locations

    • By Production Line and Work Center

  • Picklists

    • Bulk & Order

  • Shortage Allocations

  • Issue Policy

    • Issue, Backflush, None

  • Pick Policy

    • Pick+Trfr, Pick+Issue

  • Production Delivery Location



Shop floor transactions
Shop Floor Transactions

  • Common set for all Production Orders

  • Milestone Operations (WO & Repetitive)

  • WIP Queues

  • WIP Lot Trace

  • Single Backflush method

  • Consume schedules

    • Load, Demand, Supply, Allocations

  • API for “external” use

    • Kanban

    • Others


Shop floor transactions1
Shop Floor Transactions

Use one transaction for either Discrete or Repetitive


Shop floor transactions consolidated
Shop Floor Transactions - Consolidated

  • Operation Activity Reporting

  • Labor Data / Operation Time

  • Rework

  • Reject & Scrap

  • Move

  • WIP Adjustment (Queue Adjust)

  • Production Order Component Issue

  • Production Order Receipt Backflush

  • Non Productive Labor

  • 30 transactions in EE


Values realized
Values Realized

Full mixed mode manufacturing support

All functionality available everywhere

Simpler implementation – ROI

Fewer transactions

Richer functionality

Enhanced user experience

59


Manufacturing execution subcontracting
Manufacturing Execution - Subcontracting

  • Subcontract Processing

    • Scheduled Material Supply

    • Supplier Inventory control

    • Shippers for Supply

    • Ownership transfer


Manufacturing execution kanban
Manufacturing Execution – Kanban

  • Planning

    • Avg Demand Calculation

    • GRC

  • Execution

    • Move Loops

  • Closed loop Planning

    • Consume Repetitive Schedules

    • Backflush and Accounting

    • Supplier Schedules

    • Subcontract and Subcontract Supply


High level development plan1
High Level Development Plan

Beyond 2010

March

2010

Jun

2010

Sept

2011

Kanban Wkbch

Master Sched

Wkbch (MSW)

Production Sched

Wkbch (PSW)

MPS Leveling/GRC

Production Orders

Subcontract Orders & Supply

Kanban Enhancements

2010

2011

2012

63



Vision functional priorities
Vision – Functional Priorities

  • Workbenches

    • Buyer/Purchasing

    • Heijunka

    • Further build out MSW, PSW

  • Core product enhancements

  • Build out Foundation components

    • Operational metrics

    • Reporting framework

    • Process maps

    • Workflow

  • Integrations

    • EAM

    • WMS

    • Business Intelligence

    • MES


Vision functional priorities1
Vision – Functional Priorities

  • Finite Scheduling

  • Multi-Level Pegging

  • Order Promising (ATP, CTP)

  • S&OP

  • Quality


Contact information
Contact Information

Hank Canitz – Sr. Director Industry Marketing

[email protected]

1-720-238-7439

Guido Van den Broeck – Product Manager

[email protected]

011-34 93 327 20 52

Carianne Nieuwstraten- Product Manager

[email protected]

1-503-236-0025

Nicole Groves – R & D Business Analyst

[email protected]

1-805-565-4351



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