2. Overview
Premise:
– A fully integrated, real-time automated data collection
solution:
• Is essential for multi-site implementations
• Yields a very high benefit level
Evidence:
– 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
3. High-Level Goals and Benefits
GKN 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.
4. The Multi-Site / Multinational Rollout
Unique 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
5. About GKN
Company 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 Driveline's 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
6. About GKN
An 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
7. 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
8. 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
10. Technical considerations
RF 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
11. 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
12. 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
13. Cost considerations
Less hardware and software are required
because RF Express for MFG/PRO uses the
existing database and existing server
Reduced database/server ongoing maintenance
Simplified database control: QAD MFG/PRO
and RF Express for MFG/PRO work together
14. 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
15. Customer Satisfaction
Eagle consistently achieves Excellent
customer ratings not only on its product, but on
its responsiveness, support and service
For specific customer comments, visit Eagle’s
booth for a copy of What Our Customers
Say
17. 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”
18. Timelines: GKN’s and Eagle’s
Go Live February 2005---All sites
– Key support from the primary site
26. Eagle Transactions Linking the Sites
Alamance Site
produces a component to be
Roxboro Site
used in Roxboro using backflush
places an intersite request via
transaction
QAD MFG/PRO
fulfills the request using the receives the product via Pallet
Pallet Distribution Order Ship Distribution Order Receipt
transaction transaction
moves the components to the
work center location via Pallet
Move/Unlink
28. Implementation and Synergy
Effective 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 visits
Multiple pilots lead to a smooth go-live
29. Usage Between Plants
Introduced in transaction section
– Distribution orders
Critical 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 Transaction
Provides best input to MRP
30. Lessons Learned
Multi-site simultaneous go-live was
critical to success
Training must be thorough at all sites
System stress test was very important
Around-the-clock support quickly addressed
issues
– System experts were available to the users
32. Contact Information
John Malvaso Jim Miceli
IS/IT Manager for Business Applications Senior Project Manager
GKN Driveline North America (DNA). Eagle Consulting and Development
6400 Durham Road 135 Kinnelon Road, Suite 204
Timberlake, 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.com
www.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.
Editor's Notes
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.
