Download Implementing PaperLess MDCC @ Schrader Bridgeport

CISTECH XA User Conference
Implementing
Shop Floor Reporting
at Schrader Bridgeport
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
About the Division
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300 employees
3 shift operation
XA customer since 1983
Currently XA release 6
Utilize all Browser applications
Shop Floor Software:
– MDCC – Manufacturing Data Collection &
Communications
– ATM – Advanced Transaction Management
– PBLSi – Paper-Less Barcode Labeling for the iSeries
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
About the Division
• Schrader Bridgeport
– Customers
• Tier 1, 2 and 3 automotive suppliers
• Automotive aftermarket
• Industrial
– Products
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Tire valves
Fuel valves, air conditioning valves, valve cores
Pneumatic couplers and plugs
Various tire hardware equipment
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Why Implement Shop Floor Reporting
• Re-Engineering the business to support standard,
consistent, integrated business processes.
• Shop floor activity is the heart of the operation
• All material transactions were done manually
• Transaction reporting was at best one day behind
• Home grown stand alone labor reporting
• Labor reporting transactions were done manually
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Why Implement Shop Floor Reporting
• Shop floor data is fundamental for:
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Inventory control
Scheduling
Material Planning
Costing
• WIP was always a “black hole”
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
What we expected to gain
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Inventory accuracy
Labor time accuracy
Timely information
Free up material planners to do planning
Product identification
Use of discrete manufacturing orders
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Implementation Process
• Started with high level educational overviews
• Software features, functionality and setup
options
• Used a small work cell as a model / pilot
• Spent time learning and working out process
before expanding to other cells
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Implementation Process
• Key factors:
– Routing operations
– Definition and setup of production facilities
• Process:
– Defined / created production facilities
– Printed single level BOM with routing
– Reviewed with shop floor supervisors and floor
associates
– Marked up to reflect actual process
– Changed routings and BOM as needed
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Implementation Process
• Training
– Conducted 1 class room session with each
associate
• Explained process (TA, Job On, Job Off, …etc)
• Provided handouts that matched screens exactly
• Had each associate practice with touch screen
– Go live
• Provided hand holding
– Stood by their side during reporting (TA, Job On, Job Off,
…etc)
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Current Environment
• Entire factory using Paper-Less for shop floor
reporting
• Hardware
– 32 wireless kiosk stations consisting of:
• Touch screen
• HP thin client running Citrix
• Zebra Stripe label printer
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Current Environment
• Standard touch screen setup
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Processes
• Time and Attendance Transactions
• Job On Transactions
– Individual Job On transactions
– Crew Clocking transactions
• Multiple associates working on the same job
• Job Off Transactions
– End of shift Job Off reporting
– Multiple times within a shift reporting – Update Piece
Count
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Processes
• Material Issue Transactions (IP)
– Individual material issue based upon physical picking
process
– Material issue based upon BOM operation were first used
and routing operation reporting
• Manufacturing Production Receipt (RM)
– Stock location default via XA Production Facility master
and Item Warehouse record default stock location
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Processes
• Scrap Reporting
– During Job Off (SM)
– Scrap Component (SC)
• Operation complete transaction
• Manufacturing order complete transaction
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Enhancements
• Standard features and functionality
– Default stock location per production facility
• Issue material from
• Receive material into
– Trigger program to refresh during order release
– Hide EXIT and CANCEL buttons on Product Receipt
Screen
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Enhancements
• PBLSi – Paper-Less Barcode Labeling for the iSeries
– Automated custom label printing triggered by XA and
Paper-Less transactions.
• Schrader Bridgeport Enhancements
– Supervisor Report
– Employee Production Report
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Enhancements
• PBLSi – Paper-Less Barcode Labeling for the iSeries
– When shop floor employee reports production against the
first operation a 4 x 6 label is automatically produced.
– When shop floor employee reports production against
subsequent operations a ½ x 3 label is automatically
produced.
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Enhancements
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Enhancements
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Enhancements
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Paper-Less Enhancements
• Supervisor Report
Scott Kadak,
Division Information Systems
CISTECH XA User Conference
Keys To Success
• Use the experts to assist with the implementation
– Consultants
– Supervisors, shop floor associates
• Routings and Production Facilities are most
important
• Start with a small area
• Supervisor training and education are critical
• Training, persistence and patience are required with
shop floor associates
Scott Kadak,
Division Information Systems