Transcript Thirdware - Midwest User Group

IAC
Customizing QAD for a Unique Manufacturing Process
Prashant Arya | Director IT
Agenda
1
IAC Overview
2
Carpet Manufacturing Model
3
Process Mapping
4
Outsourcing Model
5
Lessons Learned
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IAC Global Profile
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$4+ Billion Global Annual Sales
Leading Supplier of Automotive Components & Systems
73 manufacturing facilities in 15 countries - 28,000 Employees
Process capabilities include
 Compression
 Injection and Blow molding technologies
 Various trimming and finishing methods
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IAC’s Core Market Leadership Segments
Doors & Trim
Systems
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Doors Panels
Armrests
Decorative appliqués
Map pockets
Switch bezels
Speaker grills
Safety components
Instrument Panels,
Consoles & Cockpits
Flooring &
Acoustic Systems
Instrument Panels
Cockpits
Center consoles
Hard & soft panels
Glove box assemblies
Air distribution
products
 Air registers
 Decorative appliqués
 Cup holder
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Utility flooring
Floor Carpets
Floor mats
Acoustic insulators
Package trays
Trunk trim
Engine insulators
Wheel arch liners
Headliner &
Overhead Systems
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Overhead systems
Headliner
substrates
Grab handles
Overhead consoles
Visors
Interior lighting
Safety systems
Other Interior &
Exterior Components
 Interior
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Cargo
Management
Load floors
Seat panels
Pillars
 Exterior
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Bumpers
Reservoir
Systems
Rocker
Panels
 Exterior trim
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Customers are Key
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Business & IT Challenges
Non ERP friendly Roll Goods Functionality that Plans Product A and Builds Product B
Identifying & Mobilizing resources to build the Roll Goods Functionality
Keep new functionality within Global QAD Template
Utilize the Governance model to drive the change
Bring in specialized Change Management & Subject Matter Consultants to manage the change if required
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Carpet Process (Rolled Goods) Overview
 IAC manufactures two types of carpets
 Woven Carpet – These are manufactured from Yarn
 Non-Woven Carpet – Manufactured from Synthetic Fiber
 Cutting and slitting rolls with traceability to original parent roll
 Manufacturing order allocation of assigned and unassigned rolls
 Inventory availability by quality of roll across plants and warehouses
 Bill of material, recipe formula and dye lot management
 Details of each carpet produced needs to maintain throughout the
manufacturing process as well as post shipment for many years
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Carpet Process Workflow(Woven)
Preparing the Yarn
Tufting
 Yarn arrives at carpet
manufacturer plant in
form tubes or cones
 These tubes or cones
further wound to
manufacture cones or
Beam sets. These cones
or Beam sets are
transported to the Tufting
machine
 In tufting process carpet
is manufactured on
specialized multi-needle
sewing machines.
 Yarn is fed from the creel ,
one tube of yarn for each
needle , and threaded
through the needles.
 A tufting machine can
produce several hundred
square yards of carpet per
day.
Dyeing
 In Dyeing process tufted
carpet rolls are sew-in
together to make a
continuous roll, which is
then fed under rods that
color the carpet.
 There are other methods
to dye the carpet.
Latex Coating / Shearing
 In Latex Coating process,
a coating of latex is
applied to both the tufted,
dyed carpets primary
backing and secondary
backing
 Shearing is process of
removing all of the little
loose ends and projecting
fibers that might have
been created during the
tufting process.
Inspection
 Inspection is the final
process where each
carpet is carefully
inspected for color
uniformity and
manufacturing defects
before it is rolled,
wrapped and shipped.
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Woven Carpet Manufacturing Process
Yarn
Assign Yarn to Creel
Issue Yarn to Creel
Cones or tubes of Yarn
purchased
The Yarn Lot is assigned to
Creel Location
Yarn is transferred to a creel
location
Inspection
Shipment
Final production & reporting
program were quality checks
are done
Greige Booking (Tufting)
Production & Reporting of
Tufted carpets
SEW-IN
WO Creation
The WO(Dyed, Latex or Shearing)
are scanned to create the
inspection records.
WO is created for each process
after this like Dyed WO, Latex
WO & Shearing WO
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Non-Woven Carpet Manufacturing Process
Fiber
Issue Fiber
Report
Production
Shipment
Inspection
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IAC Carpet Process - Challenges
Critical Quality Requirement
•Stringent quality checks at every manufacturing process of carpet
•Quality checks based on complex set of rules
•Quality checks based on governing laws of US specific to Automotive industry
•Carpet specific quality parameters maintenance
•Carpet specific Item master attributes
Allocation of Inventory
•Tufted carpet rolls needs to be allocated individually for a Work Order
•Allocated Roll should not be available for another Work Order
•QAD allocation based on logic of picking sequence i.e. date , location or expire date
•Allocated inventory is reserved but can used by other Work orders.
Production Booking
•Functionality of quality checks before booking production
•Consumption of components specific to Yarn lot and allow substitution of components
•Receive & issue of multiple lots of Finished goods and components
•QAD production report programs lack the functionality of quality checks and defect data entry.
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Key Solution Architecture Challenges
 Capturing of Detailed Information relevant to Quality and Production at every
stage
 High Degree of Complexity & varied processes in Inspection & Production
Reporting
 Approval Process for Lots & Dye Runs
 Lack of Features in QAD to support Automobile Carpet Process
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Masters – Process to QAD Mapping
Masters
•Carpet Data
•Creel
•Tufting Machine
•Dyeing Machine
•Quality Parameter
Maintenance
•Rules Group
Maintenance
•Operational Quality
•Monthly Lab Audits
•Machine Panel Set-up
•Tufting Strength
Standard
•Wet Pickup Tolerance
•Containment
Customized Screen
•Item Master Maintenance
to Additional carpet data
•Modify Work centre
Maintenance of maintain
carpet manufacturing
machines such as Creeler,
Tufting & Dyeing
•Quality parameter
maintenance were totally
customized screens
QAD Screen
•1.4.1 – Item master
Maintenance
•14.5 – Worker Centre
Maintenance
•14.13.1 – Routing
Maintenance
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Yarn – Process to QAD Mapping
Yarn
•Assign Yarn to Creel
•Issue Yarn to Creel
• Warping
•Location Transfer
•RTI
•Issue Edge Yarn
Customized Screen
•Depending upon the
functionality front end
validation screens
were designed and
data was captured
then passed to QAD
programs
QAD Screen
•3.12 – Receipts
Backward Explode
•3.4.1 – Location
Transfer
•3.7 - Issues
Unplanned
•3.9 – Receipts
Unplanned
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Greige Booking - Process to QAD Mapping
Greige Booking
•Creation of
Tufting/Dyed/Latex
Coated Work Order
•Release & Print of
Tuft Work Order
•Issue of Components
•Receive Components
•Inspection
Customized Screen
•Customized Work
order Maintenance
•Customized Multiple
Work Order Release/
print
QAD Screen
•16.10 – Components
Issue
•16.11 – Receive
Work Order
•17.1 – Labor
Feedback
•3.7 – Issues Planned
•3.9 – Receipts
Unplanned
•3.4.4 – Batch Load
Transfer
•16.1 – Work Order
Maintenance
•16.7 - Multiple Work
Order Release / Print
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Inspection - Process to QAD Mapping
Inspection
•Creation of
Tufting Work
Order
•Release & Print
of Tuft Work
Order
•Issue of
Components
Customized Screen
• Inspection was
totally
customized
solution for data
capture and
validations. Then
the QAD
production
booking
programs were
called.
QAD Screen
•16.10 –
Components
Issue
•16.11 – Receive
Work Order
•17.1 – Labor
Feedback
•3.7 – Issues
Planned
•3.9 – Receipts
Unplanned
•Receive
Components
•Inspection
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Quality - Process Mapping to QAD
•Rules Group Maintenance
•Operational Quality
•Monthly Lab Audits
•Machine Panel Set-up
•Tufting Strength Standard
•Wet Pickup Tolerance
•Containment
Quality
Audits
•Quality Stretch Audit
•Quality Weight Audit
•Quality Weight Audit Coater
•FPI Audit
•Dam Audit
•Containment
Quality Data
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Implementation Approach
Business Analysis
Review
Requirements /
Mapping
Systems Proposal
 Understand system
requirements with
the support from IAC
Business Team
 Prepare system
requirements of
current applications
and “to-be”
 Submit the system
requirements with
high level mapping
document.
 Review findings and
fine tune.
 Review system
requirements /
mapping with
Business Team.
 Finalize and obtain
concurrence on the
Solution Design /
mapping.
 Vendor Submits
fixed bid proposal
for analysis, design,
development of
System based on
approved mapping.
 IAC IT and business
team reviews and
approves the
proposal.
 Project kick-off
2 Months - Plant
1 Month – India / US
1 Month
Participation from
IAC Team
Approval from IAC
IT and Business
Team
Business / IT
commitment for the
project
Systems Analysis &
Design
Systems
Development &
launch
 Detailed Analysis,
design, technical
specification for
Custom
Developments,
extensions and
Reporting Solution.
 Approval from IAC
business and IT
teams for
development
 Develop extension
as per approved
technical
specifications
 Acceptance Testing
 Deployment
 Prepare launch plan
along with IAC
business and IT
team
4 Months
10 Months
Design Approval by
IAC IT / Business
Acceptance Testing by
IAC IT / Business
Team
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Development - Iterative Methodology
An independent team working on developing the module using QAD as the base to fit carpet requirements
Adopt Best Practices for software customizations
Iterative development
Enable business innovation through rapid ideation and prototyping
Work closely with Business SMEs within the Team to ensure that the requirements are fully met
FS & TS
creation/Approval
Code & Test
On-Site Team
creates the Iteration
Backlog
Requirements
FS & TS
creation/Approval
FS & TS
creation/Approval
Code & Test
Code & Test
Requirements
FS & TS
creation/Approval
Code & Test
Test & Fix
Defects
ITERATION CODE FREEZE
Iteration
Backlog
Requirements
ITERATION ASSESSMENT
Requirements
Continuous Integration
Up to 2 week
Iteration 3-8 weeks
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Team Structure
On-Site Team
IT Project Manager
Off-Shore Team
Business Project
Manager
QAD Experts
Development Team
Program Coordinators
Change Management
Specialists
Testing Team
Process Analyst
On-Site Team
Off-Shore Team
•Project coordinator to ensure coordination and consistent reporting
across to stakeholders
•Structure backed by a strong Governance Model to ensure timely
resolution of risks and issues
•Experts in the Business Process as well as the IT Solution
•Quality Analyst to prepare Test data and ensure expected results
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Lessons Learned
Clearly Define the Scope, Expectations and Detailed Process Review/Documentation
Prepare a Governance model and Schedule keeping in consideration resource constraints
Adopt an iterative methodology for refining the mappings and process, allowing for repeatable and
comparative testing.
Manage/Control User-centric design & Change Orders
Emphasis on Stricter Quality Norms & UAT
Familiarizing User on QAD Functionality before Analysis
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