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QAD Planning and Scheduling Workbenches
Carianne Nieuwstraten, Product Manager, QAD. IncBen Crawford, CSCP, Production and Inventory Control Manager, Superior Essex
QAD Explore 2012
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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.
Safe Harbor Statement
QAD Planning and Scheduling Workbenches
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• The Effective Enterprise• Solution overview• Superior Essex implementation review• Next steps • Vision• Summary • Questions
Presentation Agenda
QAD Planning and Scheduling Workbenches
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“An Effective Enterprise is one where every business process is working at peak
efficiency and perfectly aligned to the company’s strategic goals. ”
Effective Enterprise
QAD Planning and Scheduling Workbenches
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• Integrated view of key planning and scheduling data elements
• Ability for quick visibility to:- Supply and demand issues- Machine capacity issues- Material shortages
.. leading to a higher rate of schedule achievement
.. improving delivery schedules
.. helping reduce inventory levels
Effectiveness of Planning and Scheduling Workbenches
QAD Planning and Scheduling Workbenches
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Scheduler’s Challenge
QAD Planning and Scheduling Workbenches
Executives
ROI must improve; the stockholders are not happy!
Manufacturing
There are too many changes! Provide fixed schedules and the correct parts and delivery will improve.
Sales
Service levels are down. I need more inventory! Whatever it takes to keep the customer happy!
Engineering
There’s a new product introduction scheduled for the fall! But we need more time for design!
Finance
There’s too much cash tied up in inventory!
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Planning and Scheduling Paradigm
QAD Planning and Scheduling Workbenches
POs
Planning
DataForecast
Capacity
WOs
BOMs
Routings
WorkCenters
QOH
Safety StockShop
Calendar
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Common Scheduling Situation
QAD Planning and Scheduling Workbenches
… …
MRP DETAILSRESOURCE LOADWO MAINTENANCEDEMAND DETAILS
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MSW – Master Scheduling Workbench
QAD Planning and Scheduling Workbenches
Capacity FrameDisplays capacity information per selected resource in the Schedule Grid- Balance your planned and required capacity.
Schedule GridThe primary context of the workbench. - View and modify your production schedules for each item.
Supply/Demand FrameProvides demand & supply information per selected item in the Schedule Grid.- Primary information used for scheduling decision making.
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MSW – Master Scheduling Workbench
QAD Planning and Scheduling Workbenches
Supporting PanelsEnables master scheduling action and decision making.
Represents over 30 maintenance programs and reports!
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PSW – Production Scheduling Workbench
QAD Planning and Scheduling Workbenches
Production Order Sequence GridSchedule and sequence production orders by item attributes
Production Order BrowseSearch & group data per user specification - Drag & Drop the
orders to the desired position on the Sequence Grid.
Production Order MaintenanceView and maintain all order details
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Solution Components Tied Together
QAD Planning and Scheduling Workbenches
Months-Weeks-Days
Days Day-Shift-Intervals
Master Scheduling
Production Scheduling Release To shop Floor Execution
Master Schedule Workbench (MSW)
Create a master schedule balanced to supply / demand / resources
Maximize production efficiency through schedule optimization
Release to production with verification of
available materials
Production Scheduling Workbench (PSW)
Component Available Check (CAC)
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Recent Enhancements
QAD Planning and Scheduling Workbenches
Product structure filter
EAM integration
Co-\by-product support
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Recent Enhancements
QAD Planning and Scheduling Workbenches
Product structure filter
EAM integration
Co-\by-product support
EAM Orders Created
• No WB visualization • No consumption of WB capacity
Maintenance work starts
• No change on WB
EAM Orders Scheduled• Visualization
on WB• No impact to capacity on WB
Order Closed
• Scheduler can see work is complete and see history if desired
EAM Integration
QAD Planning and Scheduling Workbenches
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Recent Enhancements
QAD Planning and Scheduling Workbenches
Product structure filter
EAM integration
Co-\by-product support
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Availability and Documentation
QAD Planning and Scheduling Workbenches
Workbenches – general:
• eB2.1 SP4 and up, add-on• 2010.1EE and up, core
Recent enhancements• 2012 EE except for co\by• EE package – target release: May • SE package – target release: JulyDocumentation
• Installation, admin, user and training guides
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• Essex Wire was founded in Detroit, Michigan in 1930; roots based in automotive
• Acquired by Superior Telecom Inc in 1999 to form Superior Essex• Acquired by LS Cable in 2008 based in Seoul, South Korea• Corporate offices located in Atlanta, Georgia• North America Magnet Wire headquartered in Fort Wayne, Indiana• Number #1 Global Magnet Wire• Number #2 North American Magnet Wire• Number #3 Global Wire and Cable• Vertically integrated, producing own enamels and copper rod • Markets: Automotive, Commercial & Residential, Energy, Industrial,
Distribution• Global footprint• Discrete manufacturing• QAD ERP: 2008 SE
Superior Essex Overview
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Superior Essex Production Flow
QAD Planning and Scheduling Workbenches
OvenWire
Drawing
Copper
Rod
Spool
Shipping
Packaging
Enamel
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• Pain Points- No master scheduling process in place- 900 to 4000 SKUs per plant- Stock replenishment system with poor forward
visibility- Limited capacity visibility – spreadsheet system- Homegrown scheduling tools not integrated
with QAD- Schedulers searching multiple tools to gather
information for decision making- Managers needed to query multiple sources to
review results
Challenges
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• After MSW/PSW implementation- Improved customer service- Improved component material purchasing and
forecasting- Increased Scheduler confidence- Greatly improved capacity visibility- Machines grouped by capabilities
Benefits
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• Currently live at one location – Feb 2012- Kendallville, IN
• Next plant go live in June- Franklin, IN
• All 6 North American plants scheduled to be live by Jan, 2013
• Locations outside North America to be considered after these 6 are complete
Implementation Plans
QAD Planning and Scheduling Workbenches
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• Familiarize plant with MRP planning reports before go live
• Educate plant on .Net UI before go live• Group like-machines together and tie
items to respective group• Train scheduling team and encourage
MSW/PSW practicing before going live• Data cleanup is critical • Leadership and executive support is key
for success
Lessons Learned
QAD Planning and Scheduling Workbenches
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• Involve other departments- Let workbenches drive involvement
• Start simple• Move to production quickly • Hardly ever an “all or nothing”• Iterative implementation and learning
process
Implementation Considerations
QAD Planning and Scheduling Workbenches
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Next Steps
QAD Planning and Scheduling Workbenches
2012
May Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul201
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Aug Sep
SE Package
- Co-\By-product support- Product Structure Filter- EAM integration- 2012 SE support
SeptemberRelease
- Performance improvements- WO API improvement- Maintenance
- Continuous EE\SE maintenance\enhancement bundle releases- Move co-\by-product functionality into core - Support for new MFG capabilities- MPS leveling- Graphical board metaphor- Operation-based scheduling
Beyond Sept 2012
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Vision
QAD Planning and Scheduling Workbenches
Master Schedule
Material Plan
Load-Leveling Constraint-
Based Master Scheduler
Master Scheduling Workbench
Material Requirements
Planning
Production Scheduling Workbench
Finite Capacity Production Scheduler
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MPS Leveling Calculation
QAD Planning and Scheduling Workbenches
Time
Volume Demand Level
Production
Calculates a level loaded (constraint based) Master Production Schedule over a user defined period of time for a site
or group of production lines.
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Vision
QAD Planning and Scheduling Workbenches
Master Schedule
Material Plan
Load-Leveling Constraint-
Based Master Scheduler
Master Scheduling Workbench
Material Requirements
Planning
Production Scheduling Workbench
Finite Capacity Production Scheduler
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• Integrated planning and scheduling tool set
• Reduce planning and scheduling time and complexity
• Compress manufacturing response• Provide ability to create effective
plans and schedules• Enable to be proactive
Planning and Scheduling WBs Value
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• Review available documentation - QAD web site: planning and scheduling
workbenches
• Work with QAD services/partner to line up training
• Work with QAD/partner account rep to schedule demo
Next Steps After Explore
QAD Planning and Scheduling Workbenches
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Carianne NieuwstratenProduct Manager, QAD. Incczn@qad.com
Ben CrawfordProduction and Inventory Control ManagerSuperior Essexben.crawford@spsx.com
Questions & Answers
QAD Planning and Scheduling Workbenches
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