QAD Planning and Scheduling Workbenches
Increase Your Manufacturing Efficiency with QAD’s
Planning and Scheduling Workbenches
Carianne Nieuwstraten – Senior Product Manager, QAD
Chris Loerch – Sr Mgr of Plant Supply Chain, Cascade Engineering
QAD Planning and Scheduling Workbenches
Safe Harbor Statement
The following is intended to outline QAD’s general
product direction. It is intended for information
purposes only, and may not be incorporated into
any contract. It is not a commitment to deliver
any material, code, functional capabilities, and
should not be relied upon in making purchasing
decisions. The development, release, and timing
of any features or functional capabilities
described for QAD’s products remains at the sole
discretion of QAD.
2
QAD Planning and Scheduling Workbenches
What Do The Analysts Say?
“Best-in-Class manufacturers are 49% more likely to
have real-time visibility between manufacturing
operations and customer orders.”
Matthew Littlefield, AberdeenGroup, Manufacturing Operations Management:
Capitalizing on the Economic Recovery, March 2010
3
QAD Planning and Scheduling Workbenches
The Scheduler’s Challenge
4
QAD Planning and Scheduling Workbenches
Master Scheduler’s Challenge
Executives
Finance
ROI must improve; the
stockholders are not
happy!
There’s too much
cash tied up in
inventory!
Manufacturing
Engineering
There are too many
changes! Provide
fixed schedules and
the correct parts and
delivery will improve.
There’s a new
product introduction
scheduled for the fall!
But we need more
time for design!
Sales
Service levels are
down. I need more
inventory! Whatever it
takes to keep the
customer happy!
5
QAD Planning and Scheduling Workbenches
Production Scheduler’s Challenge
Manufacturing
Finance
Labor / machine
resources not available
for 2nd shift – what are
you going to do about
this?
High variances to “plan”
(extra setup, downtime,
labor), you need to
optimize your
production schedule.
Sales
Drops in a new high
priority order due
tomorrow, which order
can be moved?
Materials
You can’t change the
schedule on short notice
and expect the
materials to be
available.
6
QAD Planning and Scheduling Workbenches
Common Planning & Scheduling Situation
MASTER SCHEDULING
CAPACITY REQUIREMENTS PLANNING
7
QAD Planning and Scheduling Workbenches
The QAD Solution
8
Period
->
MRP
Month
->
Week
MSW
• Initial plan is
created by MRP
Demand
Received
Demand received
->
Day
->
Shift
PSW
Production
Planned
Production Planned
• Balance demand /
supply /resources to
ensure a feasible
and level production
plan.
->
Interval
Base
CAC
• Sequence
production orders by
item attributes and
resource allocations
to Optimize shop
floor
Production
Scheduled
Production Scheduled
->
hour
Base
Production
Dispatched
Production Dispatched
• Verify materials
available
• Release orders
• Print work orders
and schedules
• Monitor Production
& Manage
Production Order
Production
Reported
Production Reported
PSW
9
QAD Planning and Scheduling Workbenches
Cascade Engineering Case Study
10
QAD Planning and Scheduling Workbenches
Customer: Cascade Engineering
• Multi-business manufacturer
(automotive, commercial truck & bus,
solid waste & recycling, home & office)
• Leading provider of engineered
plastics systems and components (plus
growing number of sustainabilityfocused products and services)
• Headquartered in Grand Rapids, MI,
USA
• 7 manufacturing facilities in NA
• 1 manufacturing facility in Europe
• QAD 2008 SE, repetitive
Live
• April 10, 2011
11
QAD Planning and Scheduling Workbenches
Product Lines
12
QAD Planning and Scheduling Workbenches
Cascade Challenges
• Scheduling thousands of different manufactured
items at 5 plants
• Some items builtConsequences:
at one plant and used at another
• Schedule firm for 1 – 7 days, leading to frequent
changes
1. Lots of time spent wading through reports/screens
• Some customers provide forecasts, some don’t
2. High level of scheduler frustration
• Lot of screens and reports to go through
Unnecessary
errors
• 3.Difficult
to seescheduling
open capacity
• Integration with in-house shop floor system
13
QAD Planning and Scheduling Workbenches
Scheduling Carts – New Orders
• Hundreds of part numbers
-
Different colors (bodies and lids)
Different hot stamps
Different in-mold labels
Different wheel/axle combinations
• Same part can be made at multiple presses at two
different plants
• Press schedules generally loaded out 21-28 days
• 7 day firm schedule
14
QAD Planning and Scheduling Workbenches
Scheduling New Orders - Before
1. Run MRP Detail
Report
• Scan for
unscheduled
orders
4. Schedule
Explosion or
Selective MRP
• Schedule
updates auto
loaded to shop
floor
2. Print Press
Schedules
• 5-7 presses
• Find capacity
• Group like colors
5. Simulated Picklist
Item Check
• Check for
component
shortages
3. Add Parts To
Repetitive
Schedule Maint.
• Enter part #, site
production line,
start date, qty
6. Update shop
floor system
• Add run
sequence and SF
comments
Repeat entire process (1-6) for cart lids
15
QAD Planning and Scheduling Workbenches
Scheduling New Orders - After
1. Look for a
2.
red
day
or with
yellow
open
colored
capacity
items and cells on the MSW
16
QAD Planning and Scheduling Workbenches
Scheduling New Orders - After
3. Enter
4.
5.
Key ininverification
Visual
quantity
comments
on of
appropriate
remaining day
capacity
17
QAD Planning and Scheduling Workbenches
Scheduling New Orders - After
6. Component
7.
Sequence production
availability
orders
check
18
QAD Planning and Scheduling Workbenches
Scheduling Carts – Changes to Schedule
• Causes:
- Downtime
- Component/lid availability
- Change in priorities
• Remember, press schedules generally loaded out
21-28 days
19
QAD Planning and Scheduling Workbenches
Changes To Schedule - Before
1. Print Press
Schedules
2. Run MRP Detail
Report
• 5-7 presses
• Find open
capacity
3. Manipulate Press
Schedules
• What will be late
if work pushed
back?
4. Change Schedule
in Repetitive
Schedule Maint
• Enter part #, site,
production line,
start date, qty
• Move work to
another press?
5. Print press
schedules and
verify
•
Did I enter
everything
properly?
Repeat entire process (1-5) for cart lids
20
QAD Planning and Scheduling Workbenches
Changes To Schedule - After
1. Detailed press schedule visible and changeable with drag and drop on PSW
21
QAD Planning and Scheduling Workbenches
Changes To Schedule – After
2. Do
3.
4.
What
Summary
I try
will
tobe
schedule
move
lateto
if Ianother
visible
push back?
and
press?
changeable
– Demand
– MultipleDetails
on
press
MSW
schedule
Tab
visibility
22
QAD Planning and Scheduling Workbenches
Changes To Schedule - After
5. Visual
6.
Change
verification
Schedule of
– Key
remaining
quantity
capacity
on appropriate day
23
QAD Planning and Scheduling Workbenches
Benefits
• Time saved:
- Printing/reviewing reports
- Keying
• Improved visibility:
- Capacity
- Component availability
• Opportunity to standardize scheduling
process across plants
• Reduction in frustration and overtime
• Fewer scheduling errors, resulting in fewer
late shipments
24
QAD Planning and Scheduling Workbenches
Implementation Plans
• Currently live – 1 location
- Rollout – additional 4 USA plants
• Target – August 2011
25
QAD Planning and Scheduling Workbenches
Lessons Learned
• Workbenches bring together a lot of data
- What does it all mean
- Understanding navigation
- Get a big monitor
• Validate ‘conversion’
- Understand new fields and default values
• Being an early adopter meant allowing time
for debugging and fixing
• Understand and test the integration points
• .NetUI: new element for us
26
Role-Based Manufacturing Browse Collections
MFG Planning & Execution
Synchronization
27
Planning and Scheduling Process Support
Purchase Direct Materials
28
Planning and Scheduling Process Support
Monitor Material Shortages
29
Planning and Scheduling Process Support
Release Production Orders
30
Planning and Scheduling Process Support
Manage Materials
31
QAD Planning and Scheduling Workbenches
Availability & Roadmap
32
QAD Planning and Scheduling Workbenches
Availability and Documentation
•
Availability
-
Part of core EE as per 2010.1 EE
• Tied to QAD Maintenance
-
Add-on for eB2.1 SP4 through 2010 SE
• Tied to QAD Maintenance
• .Net 2.9.1
• Minimum Progress Requirements:
-
•
OE10.1C04, OE10.2A02, OE10.2B
Documentation
-
support.qad.com
•
•
•
•
-
User Guide
Administration Guide
Training Guide
Installation Guide – eB2.1/SE only
www.qad.com
• Solutions – QAD Manufacturing
-
Product Data Sheets
• Planning and Scheduling Workbenches Data Sheet
33
QAD Planning and Scheduling Workbenches
Roadmap
• Workbench enhancements
• Operational based scheduling
• Finite capacity scheduling
34
QAD Planning and Scheduling Workbenches
Summary
35
QAD Planning and Scheduling Workbenches
Planning and Scheduling WBs Value
• Reduce planning and scheduling time and
complexity
• Compress manufacturing response
• Provide ability to create effective plans and
schedules
• Enable to be proactive
36
QAD Planning and Scheduling Workbenches
Browse Collections Value
• Everyone working of the same data set
• A “workbench” created for each role to
perform their key daily tasks
37
QAD Planning and Scheduling Workbenches
Metrics Affected
Process
Single screen visibility to detailed
load vs. capacity, QOH, demand
& supply data
Benefit
Value
•Significant reduction in
planning/scheduling time
•-70 to 75%
•Reduced lead times
•-5 to 10%
•Improved customer service
•5 to 10%
Schedule production for
intermediate and final assemblies
on production lines directly from
customer demand
•Maximize throughput to
maintain minimum finished goods
and work in process inventory
•10% to 30%
•Improve customer service
•10% to 30%
•Enables load balancing against
available capacity and highlights
imbalances
•Improved resource utilization
•10 to 20%
•Improved customer service
•5 to 10%
Simulation capabilities with subassembly and purchased item
material checking capabilities
•Reduce production disruptions
due to material shortages
•-10% to 30%
•Reduce inventory
•-10 to 25%
Transportation planning
•Reduce transportation costs
•-5% to 20%
Truck load plans with supplier
38
Award Winning Application
Best Products and
Services Category Solutions for
Manufacturing
39
QAD Planning and Scheduling Workbenches
Next Steps
• Ask your account manager for a Q−Scan to
see how QAD's Planning and Scheduling
Workbenches can save your company
money
• Ask your account manager to arrange an
in−depth demo
40
QAD Planning and Scheduling Workbenches
Questions & Answers
• Chris Loerch: chris.loerch@cascadeng.com
616-975-4950
• Carianne Nieuwstraten: czn@qad.com
503-236-0025
41
www.qad.com
© QAD Inc
42