IACCustomizing QAD for a Unique Manufacturing

ProcessPrashant Arya | Director IT

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Agenda

IAC Overview

Carpet Manufacturing Model

Process Mapping

Outsourcing Model

Lessons Learned

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IAC Global Profile

$4+ Billion Global Annual Sales Leading Supplier of Automotive Components & Systems 73 manufacturing facilities in 15 countries - 28,000

Employees Process capabilities include

Compression Injection and Blow molding technologies Various trimming and finishing methods

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IAC’s Core Market Leadership Segments

Doors Panels Armrests Decorative

appliqués Map pockets Switch bezels Speaker grills Safety

components

Doors & TrimSystems

Instrument Panels, Consoles & Cockpits

Flooring & Acoustic Systems

Headliner & Overhead Systems

Other Interior & Exterior Components

Instrument Panels

Cockpits Center consoles Hard & soft

panels Glove box

assemblies Air distribution

products Air registers Decorative

appliqués Cup holder

Utility flooring Floor Carpets Floor mats Acoustic

insulators Package trays Trunk trim Engine

insulators Wheel arch

liners

Overhead systems

Headliner substrates Grab handles Overhead

consoles Visors Interior lighting Safety systems

Interior• Cargo • Manageme

nt• Load floors• Seat

panels• Pillars

Exterior• Bumpers• Reservoir • Systems• Rocker • Panels

Exterior trim

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Customers are Key

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Business & IT Challenges

Non ERP friendly Roll Goods Functionality that Plans Product A and Builds Product B

Identifying & Mobilizing resources to build the Roll Goods Functionality

Keep new functionality within Global QAD Template

Utilize the Governance model to drive the change

Bring in specialized Change Management & Subject Matter Consultants to manage the change if required

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Carpet Process (Rolled Goods) Overview

IAC manufactures two types of carpets Woven Carpet – These are manufactured from Yarn Non-Woven Carpet – Manufactured from Synthetic Fiber

Cutting and slitting rolls with traceability to original parent roll Manufacturing order allocation of assigned and unassigned rolls Inventory availability by quality of roll across plants and

warehouses Bill of material, recipe formula and dye lot management Details of each carpet produced needs to maintain throughout the

manufacturing process as well as post shipment for many years

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Carpet Process Workflow(Woven)

Preparing the Yarn

Yarn arrives at carpet manufacturer plant in form tubes or cones

These tubes or cones further wound to manufacture cones or Beam sets. These cones or Beam sets are transported to the Tufting machine

Tufting

In tufting process carpet is manufactured on specialized multi-needle sewing machines.

Yarn is fed from the creel , one tube of yarn for each needle , and threaded through the needles.

A tufting machine can produce several hundred square yards of carpet per day.

Dyeing

In Dyeing process tufted carpet rolls are sew-in together to make a continuous roll, which is then fed under rods that color the carpet.

There are other methods to dye the carpet.

Latex Coating / Shearing

In Latex Coating process, a coating of latex is applied to both the tufted, dyed carpets primary backing and secondary backing

Shearing is process of removing all of the little loose ends and projecting fibers that might have been created during the tufting process.

Inspection Inspection is the

final process where each carpet is carefully inspected for color uniformity and manufacturing defects before it is rolled, wrapped and shipped.

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Woven Carpet Manufacturing Process

YarnCones or tubes of Yarn purchased

Assign Yarn to Creel

The Yarn Lot is assigned to Creel

Location

Issue Yarn to Creel

Yarn is transferred to a creel location

Greige Booking (Tufting)

Production & Reporting of Tufted carpets

InspectionFinal production & reporting program

were quality checks are done

Shipment

WO CreationWO is created for each process after this like Dyed WO, Latex WO &

Shearing WO

SEW-INThe WO(Dyed, Latex or Shearing) are scanned to create the inspection

records.

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Non-Woven Carpet Manufacturing Process

Fiber Issue Fiber

Report Producti

on

Inspection

Shipment

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• Stringent quality checks at every manufacturing process of carpet• Quality checks based on complex set of rules • Quality checks based on governing laws of US specific to Automotive

industry • Carpet specific quality parameters maintenance • Carpet specific Item master attributes

Critical Quality Requirement

• Tufted carpet rolls needs to be allocated individually for a Work Order• Allocated Roll should not be available for another Work Order• QAD allocation based on logic of picking sequence i.e. date , location or

expire date• Allocated inventory is reserved but can used by other Work orders.

Allocation of Inventory

• Functionality of quality checks before booking production• Consumption of components specific to Yarn lot and allow substitution of

components• Receive & issue of multiple lots of Finished goods and components• QAD production report programs lack the functionality of quality checks and

defect data entry.

Production Booking

IAC Carpet Process - Challenges

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Key Solution Architecture Challenges

Capturing of Detailed Information relevant to Quality and Production at every stage

High Degree of Complexity & varied processes in Inspection & Production Reporting

Approval Process for Lots & Dye Runs Lack of Features in QAD to support Automobile Carpet Process

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Masters – Process to QAD Mapping

Masters

• Carpet Data• Creel• Tufting Machine• Dyeing Machine• Quality Parameter

Maintenance• Rules Group

Maintenance• Operational

Quality• Monthly Lab

Audits• Machine Panel

Set-up• Tufting Strength

Standard• Wet Pickup

Tolerance• Containment

Customized Screen

• Item Master Maintenance to Additional carpet data

• Modify Work centre Maintenance of maintain carpet manufacturing machines such as Creeler, Tufting & Dyeing

• Quality parameter maintenance were totally customized screens

QAD Screen

• 1.4.1 – Item master Maintenance

• 14.5 – Worker Centre Maintenance

• 14.13.1 – Routing Maintenance

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Yarn – Process to QAD Mapping

Yarn

• Assign Yarn to Creel

• Issue Yarn to Creel• Warping • Location Transfer• RTI• Issue Edge Yarn

Customized Screen

• Depending upon the functionality front end validation screens were designed and data was captured then passed to QAD programs

QAD Screen

• 3.12 – Receipts Backward Explode

• 3.4.1 – Location Transfer

• 3.7 - Issues Unplanned

• 3.9 – Receipts Unplanned

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Greige Booking - Process to QAD Mapping

Greige Booking

• Creation of Tufting/Dyed/Latex Coated Work Order

• Release & Print of Tuft Work Order

• Issue of Components

• Receive Components

• Inspection

Customized Screen

• Customized Work order Maintenance

• Customized Multiple Work Order Release/ print

QAD Screen

• 16.10 – Components Issue

• 16.11 – Receive Work Order

• 17.1 – Labor Feedback

• 3.7 – Issues Planned

• 3.9 – Receipts Unplanned

• 3.4.4 – Batch Load Transfer

• 16.1 – Work Order Maintenance

• 16.7 - Multiple Work Order Release / Print

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Inspection - Process to QAD Mapping

Inspection

• Creation of Tufting Work Order

• Release & Print of Tuft Work Order

• Issue of Components

• Receive Components

• Inspection

Customized Screen

• Inspection was totally customized solution for data capture and validations. Then the QAD production booking programs were called.

QAD Screen

• 16.10 – Components Issue

• 16.11 – Receive Work Order

• 17.1 – Labor Feedback

• 3.7 – Issues Planned

• 3.9 – Receipts Unplanned

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Quality - Process Mapping to QAD

• Rules Group Maintenance• Operational Quality• Monthly Lab Audits• Machine Panel Set-up• Tufting Strength Standard• Wet Pickup Tolerance• Containment

Quality Data

• Quality Stretch Audit• Quality Weight Audit • Quality Weight Audit Coater

• FPI Audit • Dam Audit• Containment

Quality Audits

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Implementation Approach

Business Analysis

Review Requirements

/ Mapping

Understand system requirements with the support from IAC Business Team

Prepare system requirements of current applications and “to-be”

Submit the system requirements with high level mapping document.

Review findings and fine tune.

Review system requirements / mapping with Business Team.

Finalize and obtain concurrence on the Solution Design / mapping.

2 Months - Plant

1 Month – India / US

Systems Development

& launch

Develop extension as per approved technical specifications

Acceptance Testing

Deployment Prepare

launch plan along with IAC business and IT team

10 Months

Systems Analysis &

Design

Detailed Analysis, design, technical specification for Custom Developments, extensions and Reporting Solution.

Approval from IAC business and IT teams for development

4 Months

Systems Proposal

Vendor Submits fixed bid proposal for analysis, design, development of System based on approved mapping.

IAC IT and business team reviews and approves the proposal.

Project kick-off

1 Month

Participation from IAC

Team

Approval from IAC IT

and Business Team

Acceptance Testing by IAC IT / Business Team

Design Approval by

IAC IT / Business

Business / IT commitment

for the project

OFFSHORE

ONSHORE

MODEL

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Development - Iterative Methodology

IterationBacklog

Iteration 3-8 weeks

On-Site Team creates the

Iteration Backlog

Test & Fix

Defects

Up to 2 weekContinuous Integration

Requirements RequirementsRequirementsRequirements

FS & TS creation/Appro

valFS & TS

creation/Approval

FS & TS creation/Appro

valFS & TS

creation/Approval

Code & Test

Code & Test

Code & Test

Code & Test

ITER

ATIO

N C

ODE

FRE

EZE

ITER

ATIO

N A

SSES

SMEN

T

An independent team working on developing the module using QAD as the base to fit carpet requirements

Adopt Best Practices for software customizations

Iterative development

Enable business innovation through rapid ideation and prototyping

Work closely with Business SMEs within the Team to ensure that the requirements are fully met

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Team Structure

On-Site Team

IT Project Manager

Business Project Manager

Program Coordinators

Change Management

Specialists

Off-Shore Team

QAD Experts

Process Analyst

Development Team

Testing Team

On-Site Team•Project coordinator to ensure coordination and consistent reporting across to stakeholders

•Structure backed by a strong Governance Model to ensure timely resolution of risks and issues

Off-Shore Team•Experts in the Business Process as well as the IT Solution

•Quality Analyst to prepare Test data and ensure expected results

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Lessons Learned

Clearly Define the Scope, Expectations and Detailed Process Review/Documentation

Prepare a Governance model and Schedule keeping in consideration resource constraints

Adopt an iterative methodology for refining the mappings and process, allowing for repeatable and comparative testing.

Manage/Control User-centric design & Change Orders

Emphasis on Stricter Quality Norms & UAT

Familiarizing User on QAD Functionality before Analysis