Methods Plastics Processors Utilize
to Improve Plant Floor Productivity
& Efficiency
Glenn Nowak - Vice President
Daniele Fresca – Director of Marketing
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stockholm. SWE
Who is IQMS?
 Founded in 1988 to Provide “Smart”
Management Systems for Plastic Processors
 Introduced ERP-based RealTime Machine
Monitoring in 1993
 Automate inventory transactions, monitor cycle times,
accurately report scrap & down time
 Released Windows/Oracle based ERP in 1996
 Continuous development on same platform based on
customer requirements
 Over 500 Customers with 1,000+ Locations
 Managing & Monitoring >15,000 Machines
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Productivity & Efficiency Basics
 The Best Manufacturers Understand Money is
Made on the Shop Floor
 Lean Manufacturing Strives to Eliminate or
Reduce Non-value Added Activities & Their
Associated Costs
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Plant Floor Productivity & Efficiency
 Link ERP System to Shop Floor & Warehouse
Systems
 Tie product demand to manufacturing & shipping
 Provide more timely information on production &
inventory levels
 Yield a view across the entire enterprise
 Provide accurate production costs tied to selling price
for product profitability
 Present metrics to measure productivity
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Plant Floor Productivity & Efficiency
 Automate as Much as Possible
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Eliminate Human Error & Cost
Increase Timeliness of Data Transfer
Save Time in Data Entry
Increase Data Accuracy by Eliminating Entry Errors
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Plant Floor Productivity & Efficiency
 Get Timely & Accurate Data to All Users
 Real time data vs. batch data transfer
 Provide Visibility to Data with Shop Floor User
Interfaces
 Track Labor Costs Directly to Production Jobs
 Shop floor screens to log directly into jobs
 Educate Employees
 Costs vs. profits
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Enhancement Opportunities
 Production Monitoring Systems
 Accurate information gathered automatically from
production machines (parts made, scrap & down
time)
 Real Time vs. Batch Transfer
 Wireless Warehouse Management
 Manage inventory from receiving through production
to shipping
 Hand held devices that access provide bar code
scanning of all inventory transactions in real time
 Forklift mounted systems that provide directed pick &
put away for optimizing warehouse management
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Enhancement Opportunities
 Shop Floor User Interfaces
 PC-based Terminals (optional touch screens) that can
access documents, enter scrap, view trend charts, etc.
 Hand Held PDAs that provide mobility to users
 SPC
 Data entry on shop floor via hand held devices or PCs
 Automatic feedback to users on out of spec inputs
 Trend & Control Charts from Shop Floor to Office
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Enhancement Opportunities
 Automation to PLCs
 Two-way communication to turn on equipment,
conveyor systems, palletizers, etc.
 Palletwrapper
 RowHMI
 RTLabel
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Implementing Process Improvements
 Determine Whether Building Blocks Are Set
 Sound ERP foundation
 Modules or interfaces to third party systems available
 Development platforms
 Map Process Flows & Define Procedures
 Knowing the processes allows you to improve them
 Identify Opportunities for Improvement & ROI
 Prioritize Opportunities & Select Best Options
 Implement Best Opportunities
 Update Procedures
 Train, Train, Train
 Reanalyze Opportunities
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stansted, UK
Questions?
Paso Robles, CA  Chicago, IL  Toronto, CAN  Taiwan  Stockholm. SWE
EnterpriseIQ Single Database Software System
Wireless
Inventory &
Production
Control
Product
Lifecycle
Management
Tooling &
Project
Management
Customer &
Supplier
Portals
Fixed
Assets
EDI / XML
ECommerce
RealTime
Machine
Monitoring
Quality
Process
Tracking
Preventative
Maintenance
Estimating
CRM / SRM&
Quoting
Customer
EstimatingRelationship
& Quoting
Management (CRM)
Sales
Order
Sales &Orders
Management
Supply
Supply Chain
Chain
Management
Accounting
& Financial
Finance & Accounting
Management
MRP
/ CRP
/
MRP
/ CRP
/ LRP
LRP
Job
& Process
Inventory
Costing
Management
Planning &
Scheduling
Business
Intelligence
Shipping
Shipping
Management
MS Office
Workflow
Interfaces
Business Activity
Labeling
Quality
Monitoring
Production
Control
JobWorkflow
& Process
Costing
Inventory
Control
MS
Office Interfaces
IQAlert
Labeling
Payroll
Time &
Core System
Workforce
Attendance
Outsource
Central
SPC & Data
Collection
Forecaster
Document
Control
Cost of
Quality
Multi-Plant/
Multi-Company
(ICT)