QAD Planning and Scheduling Workbenches Increase Your Manufacturing

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, Aberdeen. Group, 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 There are too many changes! Provide fixed schedules and the correct parts and delivery will improve. Engineering Sales There’s a new product introduction scheduled for the fall! But we need more time for design! 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 2 nd 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 Materials Drops in a new high priority order due tomorrow, which order can be moved? 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

-> MRP Month -> Week -> Day MSW Production Planned Demand received • 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 -> hour Base Production Dispatched • Verify materials available • Release orders • Print work orders and schedules • Monitor Production & Manage Production Order Production Reported CAC PSW SW Demand Received Shift PSW Production Planned • Initial plan is created by MRP -> M Period Ba se 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 sustainability-focused 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 built at one plant and used at another Consequences: • Schedule firm for 1 – 7 days, leading to frequent changes • 1. Some provide some don’t Lots customers of time spent wadingforecasts, through reports/screens • Lot of screens and reports to go through 2. High level of scheduler frustration • Difficult to see open capacity Unnecessary errorsfloor system • 3. Integration withscheduling in-house shop 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 2. 1. Look for a red day orwith yellow open colored capacity items and cells on the MSW 16

QAD Planning and Scheduling Workbenches Scheduling New Orders - After 3. 4. 5. Visual Key Enterininverification quantity comments on of appropriate remainingday capacity 17

QAD Planning and Scheduling Workbenches Scheduling New Orders - After 7. 6. Component Sequence production availabilityorders 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. 3. 4. Summary What Do I try will tobe schedule move late to if Ianother visible push back? and press? changeable – Demand – Multiple Details onpress MSW Tab schedule visibility 22

QAD Planning and Scheduling Workbenches Changes To Schedule - After 6. 5. Visual Changeverification Schedule –of. Key remaining quantitycapacity 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 test the integration points • . Net. UI: 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 e. B 2. 1 SP 4 through 2010 SE • Tied to QAD Maintenance • . Net 2. 9. 1 • Minimum Progress Requirements: - • OE 10. 1 C 04, OE 10. 2 A 02, OE 10. 2 B Documentation - support. qad. com • • - User Guide Administration Guide Training Guide Installation Guide – e. B 2. 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 • Maximize throughput to maintain and final assemblies on production minimum finished goods and work in lines directly from customer demand 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