Transcript Project Manufacturing - QAD West Coast User Group

Next Edition for Manufacturing & Supply Chain
Enhancing Core Product for Batch-Process Industry
SoCal + Bay Area User Groups
Robin Ward
Vita Tech
Bengt Johansson
QAD
Supply Chain & Manufacturing
March, 2009
Building for
You
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Building for You
 Minor Releases
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QAD 2009 / 2009.1 / 2010 / 2010.1
Standard Edition
Enterprise Edition
New versions complementary products
 Next Major Release
– Codename “Deming” after William Edwards Deming
– Only Enterprise Edition
– Planned for 2011
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Deming Release
 Named after W. Edwards Deming
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Deming made a significant contribution to
Japan's later renown for innovative
high-quality products and its economic power
 Planned for 2011
 Based on Enterprise Edition
 Main themes:
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The Perfect Lean Market
Further increase the functional depth of QAD Manufacturing
Improvements related to the Process Industry
 Developed in close cooperation with customers
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It is all for
You
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Deming Manufacturing Enhancement Areas
 Perfect Lean Market
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Expansion of Lean Capabilities
Extending the Value Stream Model
Total Quality Management in Supply Chain
 Convergence/Reconciliation/Standardization of Manufacturing solutions
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Combining strengths of various solution into one elegant Manufacturing framework
 Enhance the Manufacturing User Experience
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Simplified Implementation
Streamline Operations
Decision Support / Role-Based Workbenches
Improved Visibility
 Process Industry Extensions
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Pharmaceutical/Biotech
Food and Beverage
Chemical
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Perfect Lean Market - Manufacturing Enhancements
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MPS Calculation
QPS Master Schedule Workbench
QPS Production Schedule Workbench
Manufacturing Execution – Mixed Mode
 And much more….
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Master Scheduling Calculation
 Automatic Master Scheduling Calculation
 Build an 80% accurate MPS
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Balance Supply / Demand
Spread over Production Lines
Order Smoothing
Line leveling
Configurable Rules
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QPS Workbenches
 QPS Master Scheduling Workbench
 QPS Production Scheduling Workbench
 Component Availability Check
 QPS will be the only tool for production scheduling
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Master Scheduling Workbench
Capacity / Load
Production Plan
Supply / Demand
More Item, Order, Demand info
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Manufacturing Execution - Mixed Mode
 Basis for MAJOR restructuring of manufacturing
 Eliminate as many differences as possible between WO and
Repetitive
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WO on Production Line
Repetitive picklists on WO
WO Issue on Repetitive
Common Shopfloor Reporting, Backflushing
Repetitive CUM-order for WO
Kanban integrated with Repetitive
More Flexibility
Greater Control
Easier to use and implement
Lean Principles
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Enhancements
for
Process Manufacturers
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Listening to
You
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Commitment to Innovation
Industry
Standards
Vertical
Market
Analysts
Research
Competitive
Analysis
QAD Strategic
Steering Committee
Industry
Roadmap
QAD Product
Review Committee
Product
Roadmap
Product
Definition
INSIGHT™
Customer
Requests
QAD
Customers
QAD Field
Feedback
QAD Support
Feedback
QAD
PRC
Customer
Advisory Groups
Development
Groups
Technical
Foundation
Collaborative
Development
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Listening to You
 QAD has been researching Customer Requests coming from visits and
Enhancement Requests reported to us
 More then 20 QAD Customers / Partners have been participating in
defining and prioritizing which key features process manufacturers
need to be competitive today and in the future
 Based on this feedback project started to increase functional depth of QAD
Supply Chain & Manufacturing capabilities
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Process Manufacturing Advisory Board
Initial Involvement:
Met April 2008 at QAD Headquarters (10 companies)
QAD Identified Business Requirements
Team Prioritized Deliverables
QAD Created Timeline
Ongoing Conference Calls:
Periodic Conference Calls
Explorer Meetings
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Process... the Final Frontier.
These are the voyages of the star(ship) of
Enterprise Resource Planning (QAD).
Its five-year mission (hopefully less):
to explore strange new worlds (verticals),
to seek out new life (functionality)
and new civilizations (customers),
to boldly go where no
man has gone before.
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Process Manufacturing Industries
 Pharmaceutical & Biotechnology
 Processed Food & Beverages
 Chemical Products Industry
 Consumer Packaged Goods (Personal Care, Tobacco etc.)
 Other Industrials (Metal, Paper, Recycling,...)
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Main Characteristics
 Variable & Unstable Material Characteristics
 Amorphous materials
 Quality Control & Quality Assurance
 Highly Regulated Industry
 Formulas or recipes
 Batch Manufacturing
 Complex Manufacturing
 Packaging, Labeling, Picking, Shipments, Transportation – “CPG”
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Variability – AI - Potency & Batch Balancing
Aspirin
Spiraea
Ulmaria
Acetylsalicylic acid)
(
-A: Salicylic Acid
-E: Sodium
-E: Acetyl Chloride
 Potency/ Purity / Strength / Concentration Level/ Assay%
 Formula Definition
 Formula Adjustments / Batch Balancing
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Instability – Shelf Life-Based Attributes
 Date Driven Characteristics
 Quality
 Health & Safety
 Planning
 Logistics
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“Stuff” not “Things” – Multiple UOM
Alternate UOM
Dual UOM (Catch Weight)
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Quality – Lot Classifications, Lot Measurement, Lot Reference
 Extended Attributes
– Grade, Color, Grain Size,…
– pH, Moisture Content, Hardness,…
– Origin of Goods (Supplier, Country of Origin, Allergen, Chemical
Content …
 Include in processing & validations
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Quality - Lot Track & Tracing
Item & lot attributes
Lot Track & Trace
Lot Control
Returns & Recalls
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Batch/Process Manufacturing
Recipe-based Production
Attribute-based Production
Retrieval WO Productivity Data
Raw
Materials
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Mixing/
Blending
Bulk
Product
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Complex Process Manufacturing
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Packaging
Materials
Raw
Mixed-Mode Manufacturing
Materials
Mixing/
Blending
WO Stream – Linked multi-stages
Co-By-Products & Recycled Goods
Flexible Packaging Alternatives
Rule-based Formulas/Processes
Raw
Capacity & availability Tanks & Vessels
Materials
Quality Assurance/Compliancy Regulations
Finished
Products
Bulk
Product
Packaging
Packaging
Materials
Finished
Products
Mixing/
Blending
Packaging
Packaging
Materials
Raw
Materials
Mixing/
Blending
Bulk
Product
Intermediates
Processing
Bulk
Product
QC
Finished
Products
Packaging
Bulk
Product
Co-ByProducts
QC
Finished
Products
Packaging
Packaging
Materials
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Consumer Goods – Packaging, Picking & Shipment
 Packaging
– Packaging BOM
– Plan & Schedule Packaging
– Packaging and Labeling
 Extended attribute-based Picking & Shipping logic
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Product Development Plan
PHASE 3
PHASE 1
•Potency & Batch Balancing
•Alternate UOM in Supply Chain
•Recipe-Based Formulas & WO’s
•WO for Batch-Process Mfg
•Backward & Forward Lot Traceability
•Shelf Life Mgmt & Planning
•Enhancements PCC, QM
•Enhancements Co/By-Products
•Packing, Picking & Shipment
•Integration with MES, LIMS, QMS (Foundations Team)
•Recall & Returns (TBD with Customer Management-SSM)
PHASE 2
PHASE 4
•Dual UOM in Supply Chain
•Catch Weight (Sell/Ship/Invoice)
•Enhanced Manufacturing Improvements
•Supplier Qualification & Origin of Goods
•Lot Classifications & Planning/WO Execution
•Configurable/User-definable Attributes
March
2009
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September
2009
•Early Adopter/
Go-to-Market Preparations
March
2010
September
2010
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Working together with
You
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Focused Work Groups
 3 Focus Groups until end-of-2008
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Potency & Batch Balancing
Batch Manufacturing (Improving WO Execution)
Lot Traceability (Forward/Backward Lot Traceability)
 Objectives
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To
To
To
To
fully understand specific requirements, current practices, business scenarios & gaps
help define Use-/Test-cases and set-up test environments
agree on conceptual solution design
help during development process & assist with testing software
 Current Activities
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Fully understand impact all business requirements in scope of focused group
Work out Business & Test Scenarios
Define & agree on conceptual solution designs
Ensure Market Acceptance & Accelerate Product Development
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Current Activities with Work Groups
 Work Group 1.1
Potency & Batch Balancing
 Work Group 1.2
Enhancements in Formulas & Work Orders
 Work Group 1.3
Improved Lot Traceability Capabilities
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WG1.1 - Potency & Master Data
 Item, Item-Site Maintenance
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Extended Attributes Enabled
Target Potency
Potency Tolerance
Potency Enforcement
 Formula Maintenance
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Specific Target Potency values
Potency Tolerance
Potency Enforcement
Component Type, Active, Excipient,
Standard
 Customer Item, Supplier Item
Maintenance
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Target Potency
Potency Tolerance
Potency Enforcement
 Unit of Measure Master table
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Rounding factor
Improved UM Maintenacemfg
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Master Data - Items
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Unit of Measure
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Master Data - Formula
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WG1.1 - Potency & Material Management
 Inventory
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Lot Potency
Effective Quantity vs. Physical Quantity
Planning and Costing in Effective Quantities
Inventory movement in Physical Quantities
 Inventory Potency Adjustment
– New Transaction
 PO Potency aware
– Target potency
 PO Receipt
– Potency enforcement
– Physical Quantity + Potency
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Purchase Orders Receipts
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WG1.1 – Potency & WO Batch Balancing
 Potency - Planning (MRP), Inventory Valuation
– Effective Quantities
 Inventory transaction in Physical Quantities
 Work Order Batch Balancing
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Potency enforcement at allocation
Single and Multiple Active Ingredients
Auto Batch Balancing / WO BOM Adjustments at Work Order Release
Manual Batch Balancing on demand
• Before Release
• After Release
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Formula
Product
Recipe 1
Batch Qty = 1000 KG
(Physical Quantity)
Material
Type
Scalable
Potency%
Assay%
Tolerance
A1
Active
Yes
80.00%
+/- 10%
E1
Excipient
E2
% of Batch
Effective
Qty
Physical
UOM
Filler Calc
18.85%
180.00
KG
225.00
KG
yes
Yes
3.66%
35.00
KG
35.00
KG
yes
Excipient
Yes
12.57%
120.00
KG
120.00
KG
yes
E3
Excipient
Yes
2.09%
20.00
KG
20.00
KG
yes
S1
Standard
Yes
41.88%
400.00
KG
400.00
KG
No
S2
Standard
Yes
20.94%
200.00
KG
200.00
KG
No
F1
Standard
No
1.00
EA
1.00
EA
No
 Batch Total
 Active Total
 Excipient Total
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= 1000 Kg
= 180 Kg @ 80%
= 175 Kg
Ratio:
Effective
UOM
Physical
Qty
0.2 | 0.686 | 0.114
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Planned Work Order BOM
Product
Recipe 1
Batch Qty = 3000 KG
Material
Type
Scalable
Potency%
Assay%
Tolerance
A1
Active
Yes
80.00%
+/- 10%
E1
Excipient
E2
% of Batch
Effective
Qty
Physical
UOM
Filler Calc
18.85%
540.00
KG
675.00
KG
yes
Yes
3.66%
105.00
KG
105.00
KG
yes
Excipient
Yes
12.57%
360.00
KG
360.00
KG
yes
E3
Excipient
Yes
2.09%
60.00
KG
60.00
KG
yes
S1
Standard
Yes
41.88%
1200.00
KG
1200.00
KG
No
S2
Standard
Yes
20.94%
600.00
KG
600.00
KG
No
F1
Standard
No
1.00
EA
1.00
EA
No
 Batch Total
 Active Total
 Excipient Total
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Effective
UOM
Physical
Qty
= 3000 Kg
= 540 Kg @ 80% (= 675 Kg Physical)
= 525 Kg
Ratio: 0.2 | 0.686 | 0.114
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Work Order BOM after Batch Balancing
Product
Recipe 1
Batch Qty = 3000 KG
Material
Type
Scalable
Std
Potency%
Actual
Potency%
A1
Active
Yes
80.00%
85.00%
E1
Excipient
E2
% of Batch
Effective
Qty
18.59%
540.00
KG
Yes
3.89%
112.94
Excipient
Yes
13.33%
E3
Excipient
Yes
S1
Standard
S2
F1
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Physical
UOM
Filler Calc
635.29
KG
yes
KG
112.94
KG
yes
387.24
KG
387.24
KG
yes
2.22%
64.53
KG
64.53
KG
yes
Yes
41.31%
1200.00
KG
1200.00
KG
No
Standard
Yes
20.66%
600.00
KG
600.00
KG
No
Standard
No
1.00
EA
1.00
EA
No
Batch Total
Active Total
Excipient Total
Delta
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=
=
=
=
Effective
UOM
Physical
Qty
3000 Kg
540 Kg @ 85% (= 635.59 Kg Physical)
564.71 Kg
Ratio: 0.2 | 0.686 | 0.114
39.71 Kg less Phys Qty Active / More in Excipients
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WG1.2 - Enhancements in Formulas & Work Orders
 Formulas
– Scalable/Non-Scalable Component
– Alternate UM for components
– Recipe-style Process/Formula Definitions
 Work Orders
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Recipe-style Work Order Instructions
What-If Analysis
Capturing Data in Alternate UM during WO Component Issue / Allocations
Enabling Potency & Batch Balancing in al WO Functions
 Manual WO Component Allocation
– New Transaction, Similar to SO Manual Allocation
 WO Productivity Reports
– WO Variance Reports to analyze Productivity, Utilization & Yield
– WO BOM “snap-shot” for auditing and “As-Planned” vs “As-Built” analysis
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WO Manual Allocations
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WO Detail Browse
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WG1.3 – Lot Trace Enhancements
 Improve tools for Lot Trace Analysis
– Backward Lot Traceability
– Forward Lot Traceability
 Objective
– To better fulfill Regulatory Compliancy
– Decrease time spent in “recall management”
– Improve operational excellence
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Phase 1 Project Deliveries
- Potency & Batch Balancing
- Formula & WO Process Improvements
- Enhanced Lot Traceability Capabilities
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Benefits
Opportunity to have a voice in your
industry’s ERP functionality.
Educational Experience!
Good Opportunity to Network!
It’s fun!
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Next planned activities Work Groups
 WG 2.1 – Extended Attributes
 WG 2.2 – Dual UOM
 WG 2.3 – Quality
 WG 2.4 –Next Edition Manufacturing
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Conclusions
 QAD invests to enhance its products for Process Manufacturers
 QAD builds together with YOU
 We will be ready in March 2011
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It is all about
You
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For more information
 Please Contact:
– Guido Van den Broeck
Product Manager
– Bengt Johansson
Product Architect
QAD Proprietary
[email protected]
[email protected]
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thank you
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