Implementing Shop Floor Reporting at Schrader Bridgeport Scott Kadak, Division Information Systems

Division Information Systems About the Division 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

Division Information Systems About the Division Schrader Bridgeport Customers Tier 1, 2 and 3 automotive suppliers Automotive aftermarket Industrial Products Tire valves Fuel valves, air conditioning valves, valve cores Pneumatic couplers and plugs Various tire hardware equipment Scott Kadak, Division Information Systems

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

Why Implement Shop Floor Reporting Shop floor data is fundamental for: Inventory control Scheduling Material Planning Costing WIP was always a “black hole” Scott Kadak, Division Information Systems

What we expected to gain 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

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

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

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

Division Information Systems 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

Division Information Systems Current Environment Standard touch screen setup Scott Kadak, Division Information Systems

Division Information Systems 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

Division Information Systems 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

Division Information Systems Paper-Less Processes Scrap Reporting During Job Off (SM) Scrap Component (SC) Operation complete transaction Manufacturing order complete transaction Scott Kadak, Division Information Systems

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

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

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

Paper-Less Enhancements Scott Kadak, Division Information Systems

Paper-Less Enhancements Scott Kadak, Division Information Systems

Paper-Less Enhancements Scott Kadak, Division Information Systems

Paper-Less Enhancements Supervisor Report Scott Kadak, Division Information Systems

Division Information Systems 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