Transcript Zehnder Rittling Introduction

Zehnder Rittling – Visual Manufacturing & Quality
Feedback System
Production Floor Document Control and Feedback of Production Quality
Issues
James Toomey – IT Manager
Spring 2012 MWUG Conference
Monday March 19th
Agenda
1. What is Zehnder Rittling
2. Introduction – Visual Manufacturing Solution
3. System Architecture & Demonstration – Visual Manufacturing Solution
4. Question & Answer on Visual Manufacturing Solution
5. Introduction – Quality Feedback System
6. System Architecture & Demonstration – Quality Feedback System
7. Question & Answer on Quality Feedback System
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Zehnder Rittling
Company Summary
 Zehnder Rittling Organization
 150 employee subsidiary of Zehnder Group, a $700M residential and
commercial HVAC manufacturer headquartered in Switzerland
 48 North American sales reps
 150,000 SF Buffalo, NY manufacturing facility
 Manufacturing Processes
 We manufacture terminal hydronic heating and cooling equipment for
commercial applications
 Our main production cells are sheet metal fabrication, powder coating and
assembly
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Zehnder Rittling
Systems Summary
 QAD SE 2010
 Located at our sister company in the
Netherlands
 Implemented in 2009 at our site
 Factivity 3.2L
 Located in our Buffalo, NY facility
 Implemented in 2009
 Synexus Order Entry Configurator
 Custom developed solution hosted at a
3rd party in the Netherlands
 MS SharePoint Foundation 2010
 Located in our Buffalo, NY facility
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Agenda
1. What is Zehnder Rittling
2. Introduction – Visual Manufacturing Solution
3. System Architecture & Demonstration – Visual Manufacturing Solution
4. Question & Answer on Visual Manufacturing Solution
5. Introduction – Quality Feedback System
6. System Architecture & Demonstration – Quality Feedback System
7. Question & Answer on Quality Feedback System
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Zehnder Rittling – Visual Manufacturing Solution
Introduction
 Visual Manufacturing Solution Summary
 A system solution that is tightly linked to the product structure that displays
fabrication and assembly diagrams and models, as well as fabrication
CAM machine programs
 Utilizes QAD and Factivity, QAD to manage the data and Factivity to
present the documents
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Zehnder Rittling – Visual Manufacturing Solution
Introduction
 Visual Manufacturing Cost and Timeline to Implement
 Provided you have QAD and Factivity, the cost to implement was below
$2,500
 Implementation of the technology can be done in a day, however the item
and BOM setup is completely dependent on the number of documents you
need to manage in your system
 In our case we maintain around 400,000 finished good items and
750,000 sub-component assemblies, each of which contains between
5 and 30 documents
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Agenda
1. What is Zehnder Rittling
2. Introduction – Visual Manufacturing Solution
3. System Architecture & Demonstration – Visual Manufacturing Solution
4. Question & Answer on Visual Manufacturing Solution
5. Introduction – Quality Feedback System
6. System Architecture & Demonstration – Quality Feedback System
7. Question & Answer on Quality Feedback System
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Zehnder Rittling – Visual Manufacturing Solution
System Architecture
 Factivity Documents Interface
 The documents interface is an add-on component of Factivity
 Functionality out of the box
 Static document list and viewer
 Customizations for Zehnder Rittling
 Displays each operation independently and puts the documents
assigned to their respective operations
 Displays PDF files within a modal IE window using the embedded
acrobat reader
 Displays Solidworks CAD models in eDrawings
 Provides a customizable terminal interface to show and send
CAM programs via a serial interface
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Zehnder Rittling – Visual Manufacturing Solution
System Architecture
 Requirements to run the solution
 Factivity Server
 QAD
 File Repository using SMB, FTP or Windows File Share
 Workstations with Factivity Client, IE, Acrobat Reader, eDrawings and a
Serial Port (only used for CAM program transfer)
 Integration between systems
 Using the standard sync process of Factivity work orders are sent by FTP
(or SFTP) session
 Specific fields are populated in item master maintenance in QAD which
organize the documents within Factivity
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Zehnder Rittling – Visual Manufacturing Solution
System Architecture
 Our Environment
 Order entry configurator building level 1 of product BOM
 Item prefix designates the type of document (informational only)
 Drawing field designates the file extension and program to use when
building the file path in Factivity
 Factivity uses a static path for the file repository, then takes the item
number and appends the drawing field as the file extension to build
the link
 Operation in product structure designates the operation to be displayed at
in Factivity
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Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
 Example Case (Configurator & QAD Setup)
 We have parent item 11908002051A that has been created through the
order entry configurator which has assembly drawings configured in to
level 1 of the product structure for the parent item based upon the answers
to the configuration questions.
 We also have sub assembly components that have drawings and
programs in it’s sub assembly product structure
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Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
 Example Case (Configurator & QAD Setup)
 In our case I will demonstrate one SolidWorks model 11D00008704A
attached to the parent item through the configurator, and one sub
assembly 11408018998A and it’s associated documents, 11D00002656A,
11P00015139A.
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Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
 Example Case (Factivity Receipt of the Work Order)
 When a work order is created for this item, Factivity receives the work
order BOM.
 The work order BOM is checked for all items with item prefixes of 11D and
11P and based upon the data in the drawing field for those items and the
operation assigned on the product BOM, Factivity presents them in the
documents viewer in the appropriate operation using the appropriate
program.
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Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
 Example Case (Factivity Display of Documents)
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Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
 Example Case (Factivity Display of Documents)
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Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
 Example Case (Factivity Display of Documents)
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Zehnder Rittling – Visual Manufacturing Solution
System Demonstration Conclusion
 Simple to manage due to the fact that the solution uses the same logic that
is used to make a product BOM
 Highly flexible solution that can accommodate many types of documents
and production types
 Very low cost solution compared to other electronic document management
systems
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Agenda
1. What is Zehnder Rittling
2. Introduction – Visual Manufacturing Solution
3. System Architecture & Demonstration – Visual Manufacturing Solution
4. Question & Answer on Visual Manufacturing Solution
5. Introduction – Quality Feedback System
6. System Architecture & Demonstration – Quality Feedback System
7. Question & Answer on Quality Feedback System
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Agenda
1. What is Zehnder Rittling
2. Introduction – Visual Manufacturing Solution
3. System Architecture & Demonstration – Visual Manufacturing Solution
4. Question & Answer on Visual Manufacturing Solution
5. Introduction – Quality Feedback System
6. System Architecture & Demonstration – Quality Feedback System
7. Question & Answer on Quality Feedback System
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Zehnder Rittling – Quality Feedback System
Introduction
 Quality Feedback System Summary
 A MS SharePoint 2010 Foundation based solution that is launched via
Factivity to provide operators a way to initiate a quality remediation
process instantly from their terminal
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Zehnder Rittling – Quality Feedback System
Introduction
 Quality Feedback System Summary
 Provides a visual dashboard of cumulative and month to date quality
defect data to target trouble areas within the production floor
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Zehnder Rittling – Quality Feedback System
Introduction
 Quality Feedback System Costs and Timeline to Implement
 Provided you have a windows 2003 server or newer, and Factivity the cost
to implement is free.
 The time required to setup the MS SharePoint list can be done in less than
a day by an intermediate SharePoint user
 Depending on the amount of data you want to display, the setup of the
dashboard can be completed in a few days
 The setup within Factivity is simply adding a button that launches a link to
your SharePoint site using the same modal IE window that was used for
our Visual Manufacturing solution
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Agenda
1. What is Zehnder Rittling
2. Introduction – Visual Manufacturing Solution
3. System Architecture & Demonstration – Visual Manufacturing Solution
4. Question & Answer on Visual Manufacturing Solution
5. Introduction – Quality Feedback System
6. System Architecture & Demonstration – Quality Feedback System
7. Question & Answer on Quality Feedback System
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Zehnder Rittling – Quality Feedback System
System Architecture
 MS SharePoint 2010 Foundation
 Uses a SharePoint survey to
provide branching logic to help
guide the production floor
operators to the appropriate result
 * Limitations of SharePoint
surveys
 Uses simple SharePoint work
flows to distribute the information
and kick off the quality defect
resolution process
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Zehnder Rittling – Quality Feedback System
System Architecture
 Factivity and QAD
 There is no true integration between the Quality Feedback System and
Factivity or QAD
 Factivity is only a conduit to get to the system in an easy, controlled
fashion
 There are related fields in the Feedback System that identify QAD
workcenters and process failures
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Zehnder Rittling – Quality Feedback System
System Demonstration
 Our Environment
 In this case we will show a quick example of a problem with the product
paint quality
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Zehnder Rittling – Quality Feedback System
System Demonstration
 Our Environment
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Zehnder Rittling – Quality Feedback System
System Demonstration
 Our Environment
 Once the submission is completed the Quality Feedback record is sent by
email to the Quality Control department for review
 After review to ensure that the issue is valid the Quality Control technician
initiates a rework work order or delivers the product back to a workcenter
for additional work to be done
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Zehnder Rittling – Quality Feedback System
System Demonstration Conclusion
 This was just an example of what can be done using Factivity to include
other technologies in your QAD environment
 Provided you have the appropriate applications installed on the client the
possibilities of which programs can be loosely integrated into your
production floor terminals are endless
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Agenda
1. What is Zehnder Rittling
2. Introduction – Visual Manufacturing Solution
3. System Architecture & Demonstration – Visual Manufacturing Solution
4. Question & Answer on Visual Manufacturing Solution
5. Introduction – Quality Feedback System
6. System Architecture & Demonstration – Quality Feedback System
7. Question & Answer on Quality Feedback System
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