Supporting business processes and eliminating the cost of human error
in the data collection process
Automated Shop Floor Data Collection
Michael Olson
Director of IT, Continental Structural Plastics
Automated Shop Floor Data Collection
Presentation Agenda
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About CSP
Production reporting
Semi-finished inventory “Out of Control”
Need better inventory record accuracy
Current processes do not work
Who owns the data?
How did we do ?
Questions
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Automated Shop Floor Data Collection
About Continental Structural Plastics (CSP)
Continental Structural Plastics, Inc. is
a privately held company, founded in
1982 and based in Troy, Michigan with
production facilities in Sarepta,
Louisiana; Huntington, Indiana, and
Ohio.
The company manufactures structural plastic components,
bumper beam reinforcements, rocker covers, oil pans, stamped
steel seat frames, and underbody shields, as well as outer body
panels (e.g., Corvette).
It also offers composite seat bases, engine oil sumps, and
composite sunshade substrates; and molders of glass-mat
thermoplastic composites, as well as long-glass-fibre-reinforced
thermoplastic and direct-LFT composites.
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Automated Shop Floor Data Collection
About Continental Structural Plastics (CSP)
Markets
• Automotive, Heavy truck, Agricultural,
HVAC, Building Construction, Materials Sales
Technologies
Technologies
• Thermoplastics, Natural Fiber Composites,
Sheet Molding Compound, Low Pressure
Thermoplastic Composites
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Automated Shop Floor Data Collection
Where to Begin
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Define the issue
How do others do it?
Timeliness of production feedback
Are we alone?
How do we know?
- Clear understanding of process
• Inventory is highly inaccurate
• Batch process feedback
• What tools do I have available?
• QAD System
• Eagle RF Express™ for QAD Enterprise Applications
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Automated Shop Floor Data Collection
What Tools Do I Have?
Why Eagle?
• We needed to be able to handle multi-site
differences and achieve a very high degree
of accuracy; Eagle’s large installed base
indicated that they could do it
• An example of an important capability was
Eagle’s rfvalues table, which enabled us to
set up each site individually without any
custom code.
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Automated Shop Floor Data Collection
Where to Start
• What is “Root Cause”?
• Cycle count more
• Physical inventory
- What is learned from current reporting
- Can be text and screenshots or related graphics
• Cannot be us, Darn System!
- Could be “them”
- Too complex
- I don’t have time
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Automated Shop Floor Data Collection
Where to Start
• Reported twice, thrice
- What is learned from current reporting?
- How do I keep from double dipping?
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Scrap
Rework
Rejects
Cannot be us, Darn System!
- Could be “them”
• Who is currently responsible?
- Should they be?
• Write it down!
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Automated Shop Floor Data Collection
How to Implement
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Eagle “BKF” or “BKN”
How do I measure the process ?
Is existing data OK?
Big Bang or Small Bite
Pilot and Model
Auto vs. Manual / Exceptions
Write it Down / Document
Budget required
- S/W
- H/W
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Automated Shop Floor Data Collection
Summary – How Did We Do?
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Automated Shop Floor Data Collection
How Did We Do?
• Sites require different process models
• Gather feedback and measure, then
measure some more
• Inventory Integrity Improved 95%
• “Few Surprises” at physical or cycle count
• Exceptions are best performed in full screen
QAD
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Automated Shop Floor Data Collection
Next Steps
• Roll out to all sites
• Lot Control
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Automated Shop Floor Data Collection
CSP Contact
Mike Olson
Director IT
755 W. Big Beaver Road, Suite 700
Troy, Michigan 48084
248 823 5665 Office
mike.olson@cspplastics.com
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Automated Shop Floor Data Collection
Eagle Contacts
Corporate / The Americas
Bill Paone, Executive VP, Sales and Marketing
+1.973.838.5006 Ext 119
bpaone@eaglecondev.com
Europe & Africa
Robert Freeman, Director, Eagle-Europe
+44(0) 1451 812266
rmf@eagle-europe.com
Asia Pacific
Ian Watts, Director, Eagle Asia Pacific
+65-6827-9091
iwatts@eaglecondev.com
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Automated Shop Floor Data Collection
Questions & Answers?
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