Zehnder Rittling Visual Manufacturing Quality Feedback System Production

Zehnder Rittling – Visual Manufacturing & Quality Feedback System Production Floor Document Control and Feedback of Production Quality Issues James Toomey – IT Manager Spring 2012 MWUG Conference Monday March 19 th

Agenda 1. What is Zehnder Rittling 2. Introduction – Visual Manufacturing Solution 3. System Architecture & Demonstration – Visual Manufacturing Solution 4. Question & Answer on Visual Manufacturing Solution 5. Introduction – Quality Feedback System 6. System Architecture & Demonstration – Quality Feedback System 7. Question & Answer on Quality Feedback System 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 1

Zehnder Rittling Company Summary § Zehnder Rittling Organization § 150 employee subsidiary of Zehnder Group, a $700 M residential and commercial HVAC manufacturer headquartered in Switzerland § 48 North American sales reps § 150, 000 SF Buffalo, NY manufacturing facility § Manufacturing Processes § We manufacture terminal hydronic heating and cooling equipment for commercial applications § Our main production cells are sheet metal fabrication, powder coating and assembly 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 2

Zehnder Rittling Systems Summary e as el e R O bo k n Share. Point tio or ea Cr W m Ite La & r. F ee & db rd ac er k R ec ei pt r W or k de O Or rd er les ns tio ac ns ra tes t. T da en & r Up de Or 3 ipm Zehnder Rittling – Visual Manufacturing & Quality Feedback System les § MS Share. Point Foundation 2010 § Located in our Buffalo, NY facility Synexus lity ua stem o. Q y kt k. S Lin dbac e Fe § Synexus Order Entry Configurator § Custom developed solution hosted at a 3 rd party in the Netherlands Sh Factivity Sa § Factivity 3. 2 L § Located in our Buffalo, NY facility § Implemented in 2009 2/26/2021 QAD Sa § QAD SE 2010 § Located at our sister company in the Netherlands § Implemented in 2009 at our site

Agenda 1. What is Zehnder Rittling 2. Introduction – Visual Manufacturing Solution 3. System Architecture & Demonstration – Visual Manufacturing Solution 4. Question & Answer on Visual Manufacturing Solution 5. Introduction – Quality Feedback System 6. System Architecture & Demonstration – Quality Feedback System 7. Question & Answer on Quality Feedback System 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 4

Zehnder Rittling – Visual Manufacturing Solution Introduction § Visual Manufacturing Solution Summary § A system solution that is tightly linked to the product structure that displays fabrication and assembly diagrams and models, as well as fabrication CAM machine programs § Utilizes QAD and Factivity, QAD to manage the data and Factivity to present the documents 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 5

Zehnder Rittling – Visual Manufacturing Solution Introduction § Visual Manufacturing Cost and Timeline to Implement § Provided you have QAD and Factivity, the cost to implement was below $2, 500 § Implementation of the technology can be done in a day, however the item and BOM setup is completely dependent on the number of documents you need to manage in your system § In our case we maintain around 400, 000 finished good items and 750, 000 sub-component assemblies, each of which contains between 5 and 30 documents 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 6

Agenda 1. What is Zehnder Rittling 2. Introduction – Visual Manufacturing Solution 3. System Architecture & Demonstration – Visual Manufacturing Solution 4. Question & Answer on Visual Manufacturing Solution 5. Introduction – Quality Feedback System 6. System Architecture & Demonstration – Quality Feedback System 7. Question & Answer on Quality Feedback System 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 7

Zehnder Rittling – Visual Manufacturing Solution System Architecture § Factivity Documents Interface § The documents interface is an add-on component of Factivity § Functionality out of the box § Static document list and viewer § Customizations for Zehnder Rittling § Displays each operation independently and puts the documents assigned to their respective operations § Displays PDF files within a modal IE window using the embedded acrobat reader § Displays Solidworks CAD models in e. Drawings § Provides a customizable terminal interface to show and send CAM programs via a serial interface 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 8

Zehnder Rittling – Visual Manufacturing Solution System Architecture § Requirements to run the solution § Factivity Server § QAD § File Repository using SMB, FTP or Windows File Share § Workstations with Factivity Client, IE, Acrobat Reader, e. Drawings and a Serial Port (only used for CAM program transfer) § Integration between systems § Using the standard sync process of Factivity work orders are sent by FTP (or SFTP) session § Specific fields are populated in item master maintenance in QAD which organize the documents within Factivity 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 9

Zehnder Rittling – Visual Manufacturing Solution System Architecture § Our Environment § Order entry configurator building level 1 of product BOM § Item prefix designates the type of document (informational only) § Drawing field designates the file extension and program to use when building the file path in Factivity § Factivity uses a static path for the file repository, then takes the item number and appends the drawing field as the file extension to build the link § Operation in product structure designates the operation to be displayed at in Factivity 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 10

Zehnder Rittling – Visual Manufacturing Solution System Demonstration § Example Case (Configurator & QAD Setup) § We have parent item 11908002051 A that has been created through the order entry configurator which has assembly drawings configured in to level 1 of the product structure for the parent item based upon the answers to the configuration questions. § We also have sub assembly components that have drawings and programs in it’s sub assembly product structure 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 11

Zehnder Rittling – Visual Manufacturing Solution System Demonstration § Example Case (Configurator & QAD Setup) § In our case I will demonstrate one Solid. Works model 11 D 00008704 A attached to the parent item through the configurator, and one sub assembly 11408018998 A and it’s associated documents, 11 D 00002656 A, 11 P 00015139 A. 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 12

Zehnder Rittling – Visual Manufacturing Solution System Demonstration § Example Case (Factivity Receipt of the Work Order) § When a work order is created for this item, Factivity receives the work order BOM. § The work order BOM is checked for all items with item prefixes of 11 D and 11 P and based upon the data in the drawing field for those items and the operation assigned on the product BOM, Factivity presents them in the documents viewer in the appropriate operation using the appropriate program. 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 13

Zehnder Rittling – Visual Manufacturing Solution System Demonstration § Example Case (Factivity Display of Documents) 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 14

Zehnder Rittling – Visual Manufacturing Solution System Demonstration § Example Case (Factivity Display of Documents) 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 15

Zehnder Rittling – Visual Manufacturing Solution System Demonstration § Example Case (Factivity Display of Documents) 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 16

Zehnder Rittling – Visual Manufacturing Solution System Demonstration Conclusion § Simple to manage due to the fact that the solution uses the same logic that is used to make a product BOM § Highly flexible solution that can accommodate many types of documents and production types § Very low cost solution compared to other electronic document management systems 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 17

Agenda 1. What is Zehnder Rittling 2. Introduction – Visual Manufacturing Solution 3. System Architecture & Demonstration – Visual Manufacturing Solution 4. Question & Answer on Visual Manufacturing Solution 5. Introduction – Quality Feedback System 6. System Architecture & Demonstration – Quality Feedback System 7. Question & Answer on Quality Feedback System 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 18

Agenda 1. What is Zehnder Rittling 2. Introduction – Visual Manufacturing Solution 3. System Architecture & Demonstration – Visual Manufacturing Solution 4. Question & Answer on Visual Manufacturing Solution 5. Introduction – Quality Feedback System 6. System Architecture & Demonstration – Quality Feedback System 7. Question & Answer on Quality Feedback System 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 19

Zehnder Rittling – Quality Feedback System Introduction § Quality Feedback System Summary § A MS Share. Point 2010 Foundation based solution that is launched via Factivity to provide operators a way to initiate a quality remediation process instantly from their terminal 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 20

Zehnder Rittling – Quality Feedback System Introduction § Quality Feedback System Summary § Provides a visual dashboard of cumulative and month to date quality defect data to target trouble areas within the production floor 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 21

Zehnder Rittling – Quality Feedback System Introduction § Quality Feedback System Costs and Timeline to Implement § Provided you have a windows 2003 server or newer, and Factivity the cost to implement is free. § The time required to setup the MS Share. Point list can be done in less than a day by an intermediate Share. Point user § Depending on the amount of data you want to display, the setup of the dashboard can be completed in a few days § The setup within Factivity is simply adding a button that launches a link to your Share. Point site using the same modal IE window that was used for our Visual Manufacturing solution 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 22

Agenda 1. What is Zehnder Rittling 2. Introduction – Visual Manufacturing Solution 3. System Architecture & Demonstration – Visual Manufacturing Solution 4. Question & Answer on Visual Manufacturing Solution 5. Introduction – Quality Feedback System 6. System Architecture & Demonstration – Quality Feedback System 7. Question & Answer on Quality Feedback System 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 23

Zehnder Rittling – Quality Feedback System Architecture § MS Share. Point 2010 Foundation § Uses a Share. Point survey to provide branching logic to help guide the production floor operators to the appropriate result § * Limitations of Share. Point surveys § Uses simple Share. Point work flows to distribute the information and kick off the quality defect resolution process 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 24

Zehnder Rittling – Quality Feedback System Architecture § Factivity and QAD § There is no true integration between the Quality Feedback System and Factivity or QAD § Factivity is only a conduit to get to the system in an easy, controlled fashion § There are related fields in the Feedback System that identify QAD workcenters and process failures 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 25

Zehnder Rittling – Quality Feedback System Demonstration § Our Environment § In this case we will show a quick example of a problem with the product paint quality 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 26

Zehnder Rittling – Quality Feedback System Demonstration § Our Environment 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 27

Zehnder Rittling – Quality Feedback System Demonstration § Our Environment § Once the submission is completed the Quality Feedback record is sent by email to the Quality Control department for review § After review to ensure that the issue is valid the Quality Control technician initiates a rework order or delivers the product back to a workcenter for additional work to be done 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 28

Zehnder Rittling – Quality Feedback System Demonstration Conclusion § This was just an example of what can be done using Factivity to include other technologies in your QAD environment § Provided you have the appropriate applications installed on the client the possibilities of which programs can be loosely integrated into your production floor terminals are endless 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 29

Agenda 1. What is Zehnder Rittling 2. Introduction – Visual Manufacturing Solution 3. System Architecture & Demonstration – Visual Manufacturing Solution 4. Question & Answer on Visual Manufacturing Solution 5. Introduction – Quality Feedback System 6. System Architecture & Demonstration – Quality Feedback System 7. Question & Answer on Quality Feedback System 2/26/2021 Zehnder Rittling – Visual Manufacturing & Quality Feedback System 30