VALUE Learn from the experts how a major manufacturer leveraged the integration of its automated data collection (ADC) system and QAD MFG/PRO to build a sophisticated, inter-related network of sites that transfer materials and components 24 hours a day. The ADC system tracks each transfer, in real time, as the sites “feed” one another, using offsite warehouse facilities to monitor the movement of material into the manufacturing sites. Together, QAD and Eagle Consulting help this company meet the stringent requirements of Honda and other high-profile automakers, including Just In Time product delivery. FROM THE ABSTRACT Attendees will gain insight into how they can take advantage of “lessons learned” to identify the business processes and systems that make it possible to have the same visibility into a multi-site environment as they could have from a walk across the factory floor.
OverviewPremise: – A fully integrated, real-time automated data collection solution: • Is essential for multi-site implementations • Yields a very high benefit levelEvidence: – GKN Driveline and Eagle Consulting and Development will use GKN’s US implementation to demonstrate their strategic approach to multi-site implementation and how that approach yielded specific benefits
High-Level Goals and BenefitsGKN wished to: – Build a sophisticated, inter-related network of sites that could transfer materials and components 24 hours a day – Track each transfer, in real time, as the sites “feed” one another – Use offsite warehouse facilities to monitor the movement of material into the manufacturing sites – Meet the stringent requirements of Honda and other high-profile automakers, including Just-In-Time product delivery.
The Multi-Site / Multinational RolloutUnique challenges and requirements – Maintain seamless connection between sites – Transfer materials between sites efficiently – Establish and maintain high levels of visibility into the network of sites – Address differences in local equipment, process and people – Meet varying end-customer requirements
About GKNCompany background – World’s leading producer of automotive driveline components – A global tier-one supplier – 21,000 people at 49 locations in 31 countries. Power Transfer Unit GKN Drivelines PTUs are compact, lightweight, have excellent NVH (noise, vibration, harshness) characteristics. This makes them a popular choice in a large range of applications. Copyright GKN plc
About GKNAn industry leader – Closely involved with many key milestones in automotive history. A recent example: • Jan 2006 announcement: Vehicle makers plan to introduce breakthrough technology from GKN Driveline that provides lighter driveshaft components, improved fuel economy and better overall vehicle performance… including reduction in driveline noise, vibration and harshness. • This has been described as the first major change in constant-velocity-joint (CVJ) technology in more than 70 years • GKN Driveline currently produces more than 95 million CVJs per year
GKN’s Requirements External – Meet automaker requirements (e.g., Honda) – Meet end customer requirements • GM, Ford, Honda and others Internal – Replace existing automated data collection system and see significant improvements – Increase the number of transactions captured in real time – Reduce the number of disconnected systems
GKN’s Expected Gains Achieve savings – Eliminate waste Increase productivity – Gain access to more accurate reporting Improve accuracy – Reduce human intervention – Establish consistent process across sites Copyright GKN plc Leverage QAD MFG/PRO capabilities
Why chooseEagle’s solution:RF Express™ for MFG/PRO
Technical considerationsRF Express for MFG/PRO: – Provides a seamless, plug-and-play integration with QAD MFG/PRO – Is an online, real-time, PROGRESS-based automated data collection and bar coding solution – Enables all Eagle customers to enjoy the benefits of simplified data entry, portable terminals, barcode scanning/labeling, as well as integrated scale weight transactions and the ability to print portable bar code labels – Makes it possible to configure functionality on a site-specific basis
Technical considerations (continued)RF Express for MFG/PRO: – Does not require any side databases or separate server platform • multi-site implementations do not require a separate server for each physical site – Operates in Linux, Windows and UNIX environments – Supports both Progress and Oracle databases – Calls QAD MFG/PRO edit and update routines to provide real-time data checking with enhanced functionality
Technical considerations (continued)RF Express for MFG/PRO: – Supports a wide array of devices, including: • RF handheld networks – IEEE 802.11BG Direct Sequence – Fixed shop floor stations with laser scanners • RFID tags • Fixed RF printers • Portable RF printers Copyright GKN plc • Scales • Thermal transfer printers • Bumpy bar codes
Cost considerationsLess hardware and software are required because RF Express for MFG/PRO uses the existing database and existing serverReduced database/server ongoing maintenanceSimplified database control: QAD MFG/PRO and RF Express for MFG/PRO work together
Industry Acceptance and Usage Eagle has provided solutions to the QAD MFG/PRO community since 1992 Eagle’s solution is currently installed at 800 customers and over 3,000 sites worldwide Eagle is used only by QAD MFG/PRO customers, so all installations are also QAD MFG/PRO installations Eagle’s customer list includes Fortune 500 companies worldwide in every industry served by QAD Eagle’s status as a Honda-approved solution provider, as well as its experience with FDA compliance issues, enables Eagle to add value in addressing industry- specific requirements
Customer SatisfactionEagle consistently achieves Excellent customer ratings not only on its product, but on its responsiveness, support and serviceFor specific customer comments, visit Eagle’s booth for a copy of What Our Customers Say
Scope and Project Plan Initial onsite analysis July 2004 – Primary implementation site identified – Site-specific requirements identified – Initial software pilot environment setup completed Training/piloting activities Sept 2004-Feb 2005 per GKN timeline – Honda EDI/label testing – Test 50+ other ship-scenarios – GKN brought key representatives from each site to the “training house”
Timelines: GKN’s and Eagle’sGo Live February 2005---All sites – Key support from the primary site
ImplementationNuts and BoltsRF Express for MFG/PRO
Eagle User RequirementsKeep the transactions simpleMaintain Pallet/Container Reference numberCapture transactions in real time
Warehouse Management ModulePallet Distribution Order ShipPallet Distribution Order Receipt
Eagle Transactions Linking the Sites Alamance Siteproduces a component to be Roxboro Siteused in Roxboro using backflush places an intersite request viatransaction QAD MFG/PROfulfills the request using the receives the product via PalletPallet Distribution Order Ship Distribution Order Receipttransaction transaction moves the components to the work center location via Pallet Move/Unlink
Implementation and SynergyEffective use of pilot scenarios – Pilot scenarios represented real-world activities – Users caught on very quickly – Users were able to articulate the site-specific requirements – GKN used RF Express for MFG/PRO extensively to deliver training between Eagle visitsMultiple pilots lead to a smooth go-live
Usage Between PlantsIntroduced in transaction section – Distribution ordersCritical to GKN business – Uses Kanban system to drive interplant requisitions – Requisitions are fulfilled using Pallet Distribution Order Ship Transaction – Product is received 24 hours/day using Pallet Distribution Order Receipt TransactionProvides best input to MRP
Lessons LearnedMulti-site simultaneous go-live was critical to successTraining must be thorough at all sitesSystem stress test was very importantAround-the-clock support quickly addressed issues – System experts were available to the users
Global RolloutPrevious sites – AsiaThis implementation – North AmericaFuture (now!) – Europe – South America
Contact InformationJohn Malvaso Jim MiceliIS/IT Manager for Business Applications Senior Project ManagerGKN Driveline North America (DNA). Eagle Consulting and Development6400 Durham Road 135 Kinnelon Road, Suite 204Timberlake, NC 27583 USA Kinnelon, NJ 07405+1.336.364.6449 +1.973.838.5006+1.248.364.7681 (fax) +1.973.492.2758 (fax)John.Malvaso@gkndriveline.com JMiceli@EagleConDev.comwww.gkndriveline.com www.eaglecondev.com RF Express™ for MFG/PRO is a trademark of Eagle Consulting and Development. “QAD” is a registered trademark of QAD Inc. All other products or Company names herein may be trademarks of their respective owners.
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