Transcript Slide 1
If It Moves, Scan It! The Sugar Foods Story Kerry White, Sugar Foods Ray Agrusti, Eagle Global Services #1 Supplier of sugar substitutes #1 Supplier of almonds #1 Supplier of powdered, non-dairy creamer QAD Proprietary SUGAR FOODS PRODUCTS ARE CONSUMED 80 MILLION TIMES PER DAY! #1 Supplier of croutons and crunchy salad toppings Commercial Food Service Providers Retail and Consumer Non-Commercial Food Service Providers • Restaurants • Warehouse clubs • Colleges • Hotels • Supermarkets • Health Care Facilities • Mass merchandisers SUGAR FOODS PRODUCTS ARE DISTRIBUTED TO MORE THAN 850,000 OPERATORS QAD Proprietary Sugar Foods operates four manufacturing facilities, with another coming on-line later in 2008. Takes sales orders; Produces dry items, condiment type Bakery items QAD Proprietary Bakery and dry items Manufacturing Manufacturing in 4 Locations: – – – – Sun Valley, CA Villa Rica, GA Commerce, CA Mazatlan, Mexico Service the following markets: – Foodservice – Specialty Markets • Office Coffee Services (OCS) • Vending • Convenience Stores • Membership Warehouse Clubs – Retail – Mexico – and Beyond! QAD Proprietary Sun Valley, CA (180,000 sq. ft.) (5 football fields) Mazatlan, Mexico (70,000 sq. ft.) (1.5 football fields) Villa Rica, GA (340,000 sq ft.) (10 football fields) Commerce, CA (250,000 sq. ft.) (7 football fields) Challenges Less than acceptable inventory accuracy Maximize efficiency and profitability Limited granularity in transaction history Unidentifiable products with similar characteristics Meet compliance requirements for lot traceability Position for future growth QAD Proprietary Meeting the Challenges: Phase 1 Implemented QAD Eb2.1in 2006 – QAD recognized Sugar Foods with its “Rapid Implementation Award” at Explore 2007 – Discovery to GO-LIVE in 77 days QAD Proprietary Known Challenges – Specific to ADC Inventory accuracy or a single location called “OT” • Inventory that’s “Out There” somewhere Real-time information Elimination of manual logging of raw materials Track materials from receiving through production and then shipping by means of an automated system that provides full lot traceability QAD Proprietary The Right Solution for Sugar Foods Sugar Foods chose Eagle’s RF Express™ for QAD Enterprise Applications Chose Intermec Corporation’s CK31 RF handheld devices Chose Zebra Technologies 105SL bar code label printers for the shop floor QAD Proprietary Why Eagle? Strategic QAD Partner since 1992 Seamless integration with QAD EA Progress-based solution 99% data accuracy or better Real-time data capture without changes to QAD code Personal experience with Eagle’s solution – Ease of implementation and use – Hardware and device flexibility QAD Proprietary Phase 2: Leveraging QAD EA with an Automated Data Collection Solution “ERP system implementations have 50% higher benefits when integrated with an Automated Data Collection System.” Gartner Group 2001 Began ADC of raw material data in Villa Rica facility in July 2007 – Receiving – Material transfer – WIP production Completed rollout of raw material in Sun Valley in September 2007 Completed rollout of raw material in Commerce in December 2007 QAD Proprietary HOW DID WE DO IT? Made early determination that all items should be tracked utilizing pallet ID’s with very few exceptions Identified data that should be visible and scanable on all items (Label Definitions) Identified material flow and drop-off/storage locations Identified QAD transactions required to achieve maximum efficiency and traceability Identified Eagle transactions Labeled all possible storage locations (racks, floor, trailers, etc.) Performed repetitious hands-on training with users QAD Proprietary CAN WE SEE UNDER THE HOOD? QAD Proprietary QAD Proprietary QAD Proprietary POR POM POB Receiving PRV IBI IBL PRV IBI IBL PTR TRN RM Inventory Locations EAGLE RF EXPRESS for QAD EA AUTOMATED DATA COLLECTION SYSTEM PROCESS FLOW DIAGRAM Material Transfer Utilities IBI IBL SBI PRV PLO CNT CTI CTR TCT TRC UNR UNI BCP BCV RM Inventory Locations Receiving PDP TDP PTR PTR TRN PLB LBL RM Hoppers Production Staging Locations Material Handling Label Printing Status/Expire Date Change PSC IDM Production/Finished Good Inventory PRV IBI IBL BKF PTR Manufacturing QAD Proprietary Production Scanning Material Transfer FG Inventory Locations PPK PIC SPK (PL) SLB PGN Order Picking/Shipping EAGLE RF EXPRESS For QAD EA AUTOMATED DATA COLLECTION SYSTEM PROCESS FLOW DIAGRAM (SUPPLY CHAIN) POR POM POB Receiving PRV IBI IBL PMV TRN PRV IBI IBL RM Inventory Locations Material Transfer RM Inventory Locations PMV TRN PDL Receiving PLB LBL Production Staging Locations Label Printing QAD Proprietary Material Handling Utilities IBI IBL SBI PRV PLO PDL CNT CTI CTR TCT TRC UNR UNI BCP BCV EAGLE RF EXPRESS for QAD EA AUTOMATED DATA COLLECTION SYSTEM PROCESS FLOW DIAGRAM (Production) PDL PLO RM Hoppers Production Staging Locations Material Handling BKF PLB LBL Manufacturing QAD Proprietary Production Scanning Label Printing Utilities IBI IBL SBI PRV PLO PDL CNT CTI CTR TCT TRC UNR UNI BCP BCV QAD Proprietary QAD Proprietary QAD Proprietary QAD Proprietary QAD Proprietary QAD Proprietary QAD Proprietary QAD Proprietary QAD Proprietary KEYS TO SUCCESS? “Know the Flow” Simplify the process Provide as many tools as necessary Reduce keypad entry Review the process periodically QAD Proprietary Where do we go from here? Implement scanning of finished goods w/lot control – Production recording using backflush transaction – Pallet transfer between inventory locations – Sales order picking & shipping Meet specialized customer labeling requirements – UCC/EAN 128 labeling – RFID labeling – Link to ASN transaction Inter-company transfers utilizing DRP Implement all scanning functionality in Mazatlan facility Turn on lot control for raw materials QAD Proprietary Contact Information Kerry White IT Manager, Villa Rica Facility Sugar Foods Corporation +1.770.459.5225 +1.770.459.9863 (fax) [email protected] www.SugarFoods.com Ray Agrusti Senior Product Consultant / Project Manager Eagle Global Services +1.973.838.5006 +1.973.492.2758 (fax) [email protected] www.EagleConDev.com RF Express™ for QAD Enterprise Applications 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. QAD Proprietary