Automated Shop Floor Data Collection Michael Olson Director of IT, Continental Structural Plastics Supporting business processes and eliminating the cost of human error in the data collection process

About CSP Production reporting Semi-finished inventory “Out of Control” Need better inventory record accuracy Current processes do not work Who owns the data? How did we do ? Questions Presentation Agenda Automated Shop Floor Data Collection 2

3 Continental Structural Plastics, Inc. is a privately held company, founded in 1982 and based in Troy, Michigan with production facilities in Sarepta, Louisiana; Huntington, Indiana, and Ohio. About Continental Structural Plastics (CSP) Automated Shop Floor Data Collection The company manufactures structural plastic components, bumper beam reinforcements, rocker covers, oil pans, stamped steel seat frames, and underbody shields, as well as outer body panels (e.g., Corvette). It also offers composite seat bases, engine oil sumps, and composite sunshade substrates; and molders of glass-mat thermoplastic composites, as well as long-glass-fibre-reinforced thermoplastic and direct-LFT composites.

Markets Automotive, Heavy truck, Agricultural, HVAC, Building Construction, Materials Sales Technologies Technologies Thermoplastics, Natural Fiber Composites, Sheet Molding Compound, Low Pressure Thermoplastic Composites About Continental Structural Plastics (CSP) Automated Shop Floor Data Collection 4

Define the issue How do others do it? Timeliness of production feedback Are we alone? How do we know? -Clear understanding of process Inventory is highly inaccurate Batch process feedback What tools do I have available? QAD System Eagle RF Express™ for QAD Enterprise Applications Where to Begin Automated Shop Floor Data Collection 5

6 Why Eagle? We needed to be able to handle multi-site differences and achieve a very high degree of accuracy; Eagle’s large installed base indicated that they could do it An example of an important capability was Eagle’s rfvalues table, which enabled us to set up each site individually without any custom code. What Tools Do I Have? Automated Shop Floor Data Collection

What is “Root Cause”? Cycle count more Physical inventory -What is learned from current reporting -Can be text and screenshots or related graphics Cannot be us, Darn System! -Could be “them” -Too complex -I don’t have time Where to Start Automated Shop Floor Data Collection 7

Reported twice, thrice -What is learned from current reporting? -How do I keep from double dipping? Scrap Rework Rejects Cannot be us, Darn System! -Could be “them” Who is currently responsible? -Should they be? Write it down! Where to Start Automated Shop Floor Data Collection 8

9 Let’s Draw a Picture Automated Shop Floor Data Collection

Eagle “BKF” or “BKN” How do I measure the process ? Is existing data OK? Big Bang or Small Bite Pilot and Model Auto vs. Manual / Exceptions Write it Down / Document Budget required -S/W -H/W How to Implement Automated Shop Floor Data Collection 10

11 Automated Shop Floor Data Collection Sample Forms / Screens

12 Automated Shop Floor Data Collection Sample Forms / Screens

13 Automated Shop Floor Data Collection Sample Forms / Screens

14 Automated Shop Floor Data Collection Sample Forms / Screens

15 Automated Shop Floor Data Collection Sample Forms / Screens

Summary – How Did We Do? Automated Shop Floor Data Collection 16

Sites require different process models Gather feedback and measure, then measure some more Inventory Integrity Improved 95% “Few Surprises” at physical or cycle count Exceptions are best performed in full screen QAD How Did We Do? Automated Shop Floor Data Collection 17

18 Roll out to all sites Lot Control Next Steps Automated Shop Floor Data Collection

Mike Olson Director IT 755 W. Big Beaver Road, Suite 700 Troy, Michigan Office CSP Contact Automated Shop Floor Data Collection 19

Corporate / The Americas Bill Paone, Executive VP, Sales and Marketing Ext 119 Europe & Africa Robert Freeman, Director, Eagle-Europe +44(0) Asia Pacific Ian Watts, Director, Eagle Asia Pacific Eagle Contacts Automated Shop Floor Data Collection 20

Questions & Answers? Automated Shop Floor Data Collection 21