Transcript MWUG Spring 2014 March 23-25

Managing QAD Master Data
massively without IT
MWUG Spring 2014 March 23-25
Gene Tonne - Art’s Way Manufacturing
Alex Kim – 32 Soft
Art’s Way Manufacturing
• North America leader in Portable Grinder Mixer
• Since 1956
• Currently 4 different business segments
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–
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Farm Equipment
Modular Labs
Pressure Vessels
Cutting Tools
• Current business model encourages mergers and acquisitions
7/21/2015
2
Art’s Way QAD World
• QAD since 2007
– 2013SE
– QAD 2.9.6.12
– IT is the only user of character client
• Eight Domains
– 1 international
– 2 Consolidated
– VPN Tunnels
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•
•
•
•
•
•
Intersite Demand
Discrete and Advance Repetitive work orders
Heavy user of Browses and Collections
Use a few Metrics
Automated Invoices thru Dealer Portal
Just starting reviewing the MSW/PSW and BPM.
Have not modified QAD database, custom programs are bolt-on
7/21/2015
3
Moving from Discrete Work Orders to
Advance Repetitive Work Orders
•
•
•
•
•
•
Daily Production of one
8 different model numbers
Was taking over 6 hours to process paperwork
Open and close over 50 sub-assembly work orders
Issued inventory for over 500 components
Proposed Solution: Setup as a Advance Repetitive Product Line
– Flattened Bills of Materials / Removed Phantoms
– Massive change of operations to match actual production
– Massive change of work center to match location
• First model changed using QAD Item Master, Product Structure and
Routing Maintenance Programs.
– Over 80 hours of entry and many errors.
• Must be a better way?
7/21/2015
Googled QAD 3rd Party providers
4
Change over Process
• Established new Part Number with Art’s Way Part Number - New
• Copy product structure and router to New Part Number
• Downloaded into 32 Soft Product Structure Maintenance Excel Loader
– Made changes to Remarks/ Operations/ Qty / Eff End / Structure Type
plus validated other information.
– Heavily used remarks and reference because of the flattening.
– Cut and paste flattened structures
• Once completed saved in Excel and uploaded to QAD
• Used Excel spreadsheets for auditing product structure by operation.
Component
Description
Rev
Reference
Eff Start
Eff End
Qty per
Structure
Type
Remarks
Scrap
Lead Time
Offset
OP
Seq #
Forecast
%
005200
Washer, Flat 1/2 STD 9/1
A
05-FR-529510
02/20/2012
4.00
05-FR-529510-Assembly
0.00
5
1
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
05-FR-582040
02/20/2012
10.00
05-FR-582040
0.00
5
2
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
05-FR-583000
02/20/2012
4.00
05-FR-583000
0.00
5
3
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
08-FR-583000
02/20/2012
4.00
08-FR-583000
0.00
8
4
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
08-FR-584320
02/20/2012
6.00
08-FR-584320
0.00
8
5
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
09-FR-581090
02/20/2012
8.00
09-FR-581090-Assembly
0.00
9
6
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
09-FR-583000
02/20/2012
7.00
09-FR-583000
0.00
9
7
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
09-FR-584900
02/20/2012
6.00
09-FR-584900-AF
0.00
9
8
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
10
02/20/2012
12.00
0.00
10
9
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
11
02/20/2012
12.00
0.00
11
437
100.00%
005200
Washer, Flat 1/2 STD 9/1
A
12-FR-583000
02/20/2012
4.00
0.00
12
10
100.00%
7/21/2015
12-FR-583000
Option
Group
Process
5
Change over Process (cont.)
•
Downloaded into 32 Soft Routing Maintenance Excel Loader
– made changes to Work Center / Description/ Set Time / Run Time
plus validated other data
•
Once completed Saved to Excel and uploaded into QAD
Routing Maintenance
Routing code
584370
584370
584370
584370
584370
584370
584370
584370
Operation Start Date
5
6
7
8
9
10
11
12
02/20/2012
02/20/2012
02/20/2012
02/20/2012
02/20/2012
02/20/2012
02/20/2012
02/20/2012
Mch per
Overlap Queue Wait
Operation
Units
Time
Time
1
0
0.0
0.0
1
0
0.0
0.0
1
0
0.0
0.0
1
0
0.0
0.0
1
0
0.0
0.0
1
0
0.0
0.0
1
0
0.0
0.0
1
0
0.0
0.0
End Date
Std OP Work center Mch
3470
4001
5020
5025
5030
5035
5040
5045
Milest Subco Setup Run
Setup
one
ntr LT Crew Crew
Time
yes
0
1.0
1.0
0.0
yes
0
1.0
3.0
0.0
yes
0
1.0
1.0
0.0
yes
0
1.0
1.0
0.0
yes
0
0.0
1.0
0.0
yes
0
1.0
1.0
0.0
yes
0
1.0
1.0
0.0
yes
0
1.0
1.0
0.0
1
Description
584370 GM #5 Stage
584370 GM #6 Stage
584370 GM #7 Stage
584370 GM #8 Stage
584370 GM #9 Stage
548370 GM #10 Stage
584370 GM #11 Stage
584370 GM #12 Stage
Run Time
1.0
3.0
1.66
2.5
3.5
3.0
7.5
4.8763
Move
Yield % Tool Code Supplier
Time
0.0 100.00
0.0 100.00
0.0 100.00
0.0 100.00
0.0 100.00
0.0 100.00
0.0 100.00
0.0 100.00
Inventory Subcontr
Value
Cost
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
0.0
Purchase
Move Next Auto Labor
Orig.
Line
Order
Operation
Report
Start.date
Grinder assembly Production Stage #5 Install 1000 Hammermill and Air System parts Combine parts
0 yesfrom the following
no
drawings:
02/20/2012
__________________________________________
Grinder Assembly Production Stage #6 Prep and Paint 584370 GM ____________________________________________________________________________
0 yes
no
02/20/2012
584380 Paint & Dec
Grinder assembly Production Stage #7 Install Tires, Windows,Decals Combine parts from the following
0 yes drawings:
no _______________________________________________________
02/20/2012
Grinder Assembly Production Stage #8 Install Supplement Hopper, Hammermill shielding, Door,0Lights,
yes Auger Feeder
no
Mounts,02/20/2012
Fenders Combine parts from the following drawings: ___
Grinder Assembly Production Stage #9 Combined parts from the following drawings ____________________________________________________________________________
0 yes
no
02/20/2012
18
Grinder Assembly Production Stage # 10 Combining parts from the following drawings: ____________________________________________________________________________
0 yes
no
02/20/2012
Grinder Assembly Production Stage # 11 Combine parts from the following drawings: ____________________________________________________________________________
0 yes
no
02/20/2012
5
Grinder Assembly production stage #12 Combining parts from the following drawings: ____________________________________________________________________________
0 yes
no
02/20/2012
Comments
7/21/2015
WIP Item
6
Change over Process
• After verification of structure and router.
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Performed cost rolls to validate changes and improvements
Copied XXXXXX to XXXXXX-OLD
Deleted XXXXXX
Copied XXXXXX-New to XXXXXX
Setup Production Lines
Deleted Work Orders
Setup Schedule
Regenerated MRP
Monitor Production with Negative Inventory Browse and
Operations Browse
7/21/2015
7
Merger and Acquisition Process
This is what data and QAD
looks like to a new acquisition
•
1,206,926 5%
1,206,926 5%
1,206,926 5%
1,206,926 5%
Sales - Baler Whole Good
79,000
%
79,000
%
79,000
%
79,000
%
Sales - AW Ser Parts
10,945
%
10,945
%
10,945
%
10,945
%
Sales - AW Ser Parts
1,423
%
and
they
are
all
tuned
into
radio
station
1,423
%
1,423
%
1,423
%
Sales - AW Ser Parts
160,019 1%
160,019 1% WIIFM
160,019 1%
160,019 1%
Sales - AW Ser Parts
6,821
%
6,821
%
6,821
%
6,821
%
Sales - AW Ser Parts
20,487
%
20,487
%
20,487
%
20,487
%
Sales - AW Ser Parts
8,938
%
8,938
%
8,938
%
8,938
%
Sales - AW Ser Parts
112
%
112
%
112
%
112
%
Sales - AW Ser
Parts
130,340 1%
130,340 1%
130,340 1%
130,340
1%
Sales - AW Ser Parts
(3,458) %
(3,458) %
(3,458)
%
(3,458) %
Sales - AW Ser Parts
(11,669) %
(11,669)
%
(11,669) %
(11,669) %
Sales - AW Ser Parts
(2,951)
%
(2,951) %
(2,951) %
(2,951) %
Sales - AW Ser Parts
1,088
%
1,088
%
1,088
%
1,088
%
Sales - AW
Ser Parts
0
%
0
%
0
%
0
%
7/21/2015
8
Faster implementation of Mergers or
Product acquisitions
• Fast implementation of 3 acquisitions and two product lines
– Three in the last two years
• Normally less than 2 weeks from signing.
• Little or no sharing of data prior to signings
– Used custom CIM Loader for massive data import
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•
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•
7/21/2015
Vendors, Item Master, Customer, Routing, etc.
Some acquisitions had all the information, some did not.
One had routers in product structure,
One had no routers
9
Faster implementation of Mergers or
Product acquisitions
• Fast implementation of 3 acquisitions and two product lines
– Once data imported used 32 Soft for data cleansing by planning group
and acquisition company personnel
• Item Master Maintenance
• Routing Maintenance
• Product Structure Maintenance
– Used Excel Spreadsheets to manipulate data and as a training aids
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•
•
•
•
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Perform calculation converting feet to inch, hours to minutes
Find and replace functions
Mass entry of routing codes, work centers changes, etc.
Converted planning criteria Min, Max, Multiple, Order qty, Buyer/Planners, etc.
Sort into different group
Purge obsolete data
– Validated changes with product cost rolls
• Change from NEW to ACT
7/21/2015
10
Faster implementation of Mergers or
Product acquisitions
• Fast implementation of acquisitions
– Why 32 Soft or other 3rd party loader
• Its quick and easy.
• People understand Excel
– do not need to know the QAD Software.
• Frees IT to work on more intensive programming issues
– not data entry.
• Easy to transfer between sites.
• Massive changing of Item Master Data.
– Buyer/Planners, Prod Line, Groups, min, max, multiples
• People can update large amounts of data on the spreadsheet with copy
and paste, find and replace, calculations, etc.
• Use as a Training Aid
• Makes training in the QAD world a lot easier to understand.
7/21/2015
11
End Results
• Advance Repetitive vs Discrete Work Order
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–
–
–
3 work orders vs over 50 work orders
12 Total Operations
10 minutes processing vs +6 hours
Forces greater Inventory accuracy
• Structure and Routing Operations accurate
• Monitor by Negative Inventory Browse
– Moved three other lines to Advance Repetitive
– Plans to continue convert products to AR
• Fast implementation of acquisitions
– Quick implementation of new products or acquisition – 2 weeks
– Utilizes resources other than IT
– Data conversion is not a bottleneck to change.
7/21/2015
12
• Helping QAD users since 2001
• Customers are ranging in sizes from small
private firms to large multi-national public
companies
32 Soft Data Loaders
QAD Users can…
•Transform days-worth of work into minutes of work -- risk-free
•Optimize human resources
•Increase in data quality
•Eliminate costly data processing bottle necks
IT Managers can…
•Reduce time spent on data management tasks and cumbersome uploads
•Install easily in 30 minutes
•Enjoy complete peace of mind with built-in safety and security measures
Senior Management will …
•
•
Appreciate quick and tangible return on investment
Delight in the overall low Cost of Ownership
Reporting, Maintenance and
Analytical Tool Rolled Into One!
•Manage thousands of records in 60 seconds
•Make massive data updates at once in easy-to-use Excel
•Use Excel tools to analyze data
•Quick and accurate data management
•Precise and timely business decision-making ability
•Increased productivity
•Improved flexibility and cost reduction
•Fully SOX compliant
Quickly, easily, and safely
upload revised data to QAD
•Data Loaders validate the data against genuine QAD logic.
•If an error is found in the data during the upload, cells with errors are
instantly highlighted, so the user can quickly identify and correct any
problems before beginning the upload again.
•Data Loaders also use CIM load mechanism in the background. That means
your Excel data is automatically entered into QAD just as if it had been
manually keyed in, ensuring no partial upload of batched records ever occurs.
•If there is an error in any one record within the batch, Loaders will notify the
user and won’t proceed with the batch upload until appropriate adjustments
have been made.
What Data Loaders can do for you?
QAD users now can …
•Handle complicated processes quickly, accurately and risk free
•Get instant results when managing volume ERP data such as:
Item Master
Item Site Planning Data
Pricing
BOM
Routing
Supplier/Customer Items
Master Comments
Inventory Transfers
Inventory Status Change
Cycle Count Results
Supplier/Customer/Ship-to
GL transactions
GL Budget
AP Vouchers
Fixed Assets
SIM Cost sets
AR Cash App
AR CR/DR Memos
Unapplied payments
GL Analyzer
Check Cancellation
EMT
Sales Orders
Work Orders
Purchase Orders
Forecast
Customer Schedule
Production Schedule
Supplier Schedule
WO Backflush
WO Component issue
WO Labor Feedback
PO Receipts
•Reduce the need for IT experts or outsourced consultants
•Enjoy quick return on investment
How it works?
Internal Users
QAD Database Server
QAD Database
Progress 4GL
Excel Template
Port 10032
TCP/IP
Java Messaging Service
Q&A