Shatter the Pain Chain Presented by Judy Gardner

Shatter the Pain Chain Presented by Judy Gardner – Walbro Don Lindsey – CESI Nancy Mc. Crimmon – 32 Soft Inc. March 20, 2018

AGENDA § § § 32 Soft Session Objectives Introduction of Speakers CESI WALBRO Q&A

ABOUT 32 SOFT Assisting QAD users since 2001: § § § Enhance QAD performance Collaborate with clients Provide expert consultation Develop unique solutions Empower end users Free up IT resources

OBJECTIVE Review and assess case studies: § Life Science Company § Global Manufacturer of Small Engine Components

INTRODUCTIONS Today’s Team: § Nancy Mc. Crimmon – 32 Soft § Don Lindsey – CESI § Judy Gardner – Walbro

CESI - ERP EVOLUTION § § § § § 1995 - Navision 2000 - Great Plains 2007 - Implemented QAD 2008 - Add SSM and GRS Functionality § § 2015 – QAD Fixed Asset Module 2016 - EMT 2017 - Requisition Plus 2018 – Upgrade to QAD EE 2018 2009 - Upgrade from. NET 1. 1 to. NET 2. 9 2012 - Upgrade from SE to EE 2013 - Eagle Bar Coding 2013 - Install 32 Soft PO Requisition System 2014 - Internationalization thru Multiple Domains

CESI - VOLUMES DEPARTMENT Facilities Finance IT Operations QC R&D Sales Supply USERS TOTAL: 3 10 8 18 4 79 6 8 139

WALBRO - ERP EVOLUTION § § § § 1997 QAD 6. 5 1999 QAD 7. 1 2005 QAD e. B. 2 2007 QAD 2007 e. B. 2. 1 Multi domain 2011 QAD 2010 SE 2012 32 Soft Intro – Simulated Cost Set 2013 Supplier/Customer Data Loaders 2014 Purchased 12 Loaders § 2016 EMT Between Walbro Sites § 2017 QAD 2014 SE

WALBRO - VOLUMES

DATA LOADERS – CONSISTENCY! § Get familiar with one… § Enter CSV List of Items, Prod Line, Work Order, etc. § Import files to pre-populate § Online Applications § Ease of Use

ITEM PLANNING

SET UP

LOGIN

SELECTION CRITERIA

DOWNLOAD

QAD BEFORE

CHANGE DATA

UPLOAD DATA

UPLOAD SUCCESSFUL

QAD AFTER

CESI - CYCLE COUNT ISSUES Issues: § § Weekly cycle count process Multiple sites Laborious process for manually entering data Both Initial and Recounts

CESI - SOLUTION: DATA LOADERS Data Loader for 3. 1 – Cycle Count Worksheet Print

CESI - MASTER DATA - DEFINING ITEMS Issues: § New End Products – must create many § System of Record = Master Control § Process is laborious: to manually enter 83 Item Master fields, 20 Item – Site Inventory fields and 48 Item – Site Planning fields, and enter data Items BOM’s, Routing § And maintain over time § Complex DNA Lots Batches, Size Uo. M § People with knowledge needed

CESI - SOLUTION: DATA LOADERS Data Loaders for Master Data • 1. 4. 1 - Item Master Maintenance • 1. 4. 16 - Item-Site Inventory Data Maint • 1. 4. 17 - Item-Site Planning Maintenance

CESI - PRODUCT STRUCTURE Issues: § § § § § 4, 752 New BOMS for New Products in 2017 System of Record = Master Control Previously maintained a Picture of 13. 8. 1 in Master Control as Control Now we use Soft Loader Very complicated structures and processes for manually entering data. NET entry, Desktop entry Costing New 13. 5 and 15. 5 13. 18. 1 – BOM Report 15. 18. 1 – Formula Report

CESI - SOLUTION: DATA LOADERS Data Loaders for Master Data • 13. 5 - Product Structure Maintenance • 15. 5 - Formula Maintenance • 15. 1 - Formula Code Maintenance Controlled Document in Master Control. People collaborate on changes. Then, we approve and upload to QAD.

CESI - INSTALLED BASE Issues: § Voluminous 11. 3. 1 and 11. 3. 5 Transactions between Domains and Sites § Laborious Process for Manually entering data Typical of SSM – 35 Fields in 11. 3. 1, 9 fields in 11. 3. 5 § R-Parts – Refurbished and Repaired Parts § Software – Manifest Log Report, output from the instrument with Serial #’s § Xml and txt § Records in Installed Base = 8, 291 § Records in Installed Base Configuration = 21, 652

CESI - SOLUTION: DATA LOADERS Data Loaders for Installed Base • 11. 3. 1 -Installed Base Item Maintenance • 11. 3. 5 -Installed Configuration Maint Add – Move – Update

CESI - PURCHASE REQUISITIONS Issues: § High Daily Volumes of Memo Type Requisitions 43, 000 since 2016 § Sox Issues § Approval Process § Attachments § Arduous Process for Manually entering data into 5. 2. 3 - Requisition Maintenance

CESI - SOLUTION: DATA LOADERS &… Online Application for Requisition Plus Attachments Approvers

WALBRO - EMT/INTER-COMPANY TRANSFER Issues: § Transactions between domains and sites § Voluminous PO and SO § Burdensome Process for Manually entering data

CHALLENGES § § § Time zones between plants Languages (Japanese, Chinese, Spanish) Time constraints (not enough time for daily manual entry) Plant communication issues Air shipments between plants causing lost revenue Purchases from internal suppliers: • 60% Thailand • 20% China • 40% Mexico

WALBRO - SOLUTION: EMT Data Loader for EMT

WALBRO - WORK ORDER BUFFER Issues: § § How to Manage Work Orders Changes What Work Orders are “hot” Communication between Departments Communication between Shifts

WALBRO - SOLUTION: WORK ORDER BUFFER

WALBRO - COST SIMULATION THRU BOM Issues: § § § Having Time restraints To customer BOM “Mock up” Pricing issues Number of customer request New Product – how to cost

WALBRO – BOM COST SIMULATION

WALBRO - MSW/PSW WORK ORDER Issues: § § § Part Shortages for Work Orders QAD’s MSW/PSW Difficult Challenging to see demand scheduled to production Issues with capacity What “if” scenarios