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

2 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. Safe Harbor Statement QAD Planning and Scheduling Workbenches

“Best-in-Class manufacturers are 49% more likely to have real-time visibility between manufacturing operations and customer orders.” Matthew Littlefield, AberdeenGroup, Manufacturing Operations Management: Capitalizing on the Economic Recovery, March 2010 What Do The Analysts Say? QAD Planning and Scheduling Workbenches 3

The Scheduler’s Challenge QAD Planning and Scheduling Workbenches 4

Master Scheduler’s Challenge QAD Planning and Scheduling Workbenches Executives ROI must improve; the stockholders are not happy! Manufacturing There are too many changes! Provide fixed schedules and the correct parts and delivery will improve. Sales Service levels are down. I need more inventory! Whatever it takes to keep the customer happy! Engineering There’s a new product introduction scheduled for the fall! But we need more time for design! Finance There’s too much cash tied up in inventory! 5

Production Scheduler’s Challenge QAD Planning and Scheduling Workbenches Manufacturing Labor / machine resources not available for 2 nd shift – what are you going to do about this? Sales Drops in a new high priority order due tomorrow, which order can be moved? Materials You can’t change the schedule on short notice and expect the materials to be available. Finance High variances to “plan” (extra setup, downtime, labor), you need to optimize your production schedule. 6

Common Planning & Scheduling Situation QAD Planning and Scheduling Workbenches MASTER SCHEDULING CAPACITY REQUIREMENTS PLANNING 7

The QAD Solution QAD Planning and Scheduling Workbenches 8

Period - > Month - > Week - > Day - > Shift - > Interval - > hour Initial plan is created by MRP Demand Received Balance demand / supply /resources to ensure a feasible and level production plan. Production Planned Sequence production orders by item attributes and resource allocations to Optimize shop floor Production Scheduled Verify materials available Release orders Print work orders and schedules Production Dispatched Monitor Production & Manage Production Order Production Reported Base MSW PSW Production Planned (MSW) Capacity & Load Planning Capacity & Load Planning Manage Scheduling Horizon Manage Scheduling Horizon Apply Data Groupings/Filters Apply Data Groupings/Filters Select Views (daily-weekly-monthly) Select Views (daily-weekly-monthly) Apply Totaling (KYB) Apply Totaling (KYB) Apply Leveling (KYB) Apply Leveling (KYB) Production Planned (MSW) Capacity & Load Planning Capacity & Load Planning Manage Scheduling Horizon Manage Scheduling Horizon Apply Data Groupings/Filters Apply Data Groupings/Filters Select Views (daily-weekly-monthly) Select Views (daily-weekly-monthly) Apply Totaling (KYB) Apply Totaling (KYB) Apply Leveling (KYB) Apply Leveling (KYB) Production Planned (Base) Auto-Firm Auto-Firm Manage Production Order Manage Production Order  Header Attributes  Operation Attributes  Date & Times Production Planned (Base) Auto-Firm Auto-Firm Manage Production Order Manage Production Order  Header Attributes  Operation Attributes  Date & Times Many new capabilities + 60> reports, inquiries, maintenance and process programs rolled up into the new Production Scheduler Production Planned Production Scheduled Production Dispatched Production ReportedDemand received CAC Demand Received (MSW) Exception Based Visual Indicators Exception Based Visual Indicators Filtering by Exceptions Filtering by Exceptions Control Content - Demand/Supply Control Content - Demand/Supply Control Demand Sources Control Demand Sources Demand Received (MSW) Exception Based Visual Indicators Exception Based Visual Indicators Filtering by Exceptions Filtering by Exceptions Control Content - Demand/Supply Control Content - Demand/Supply Control Demand Sources Control Demand Sources Demand Received (Base) Integrated CRP calculates operation dates Integrated CRP calculates operation dates Demand Detail Drilldown Demand Detail Drilldown Monitor Inventory Monitor Inventory Demand Received (Base) Integrated CRP calculates operation dates Integrated CRP calculates operation dates Demand Detail Drilldown Demand Detail Drilldown Monitor Inventory Monitor Inventory Production Scheduled (PSW) Sequence production within days & shifts Sequence production within days & shifts Dynamically Configurable Structure Dynamically Configurable Structure Dynamically build multi-views to sequence between resources Dynamically build multi-views to sequence between resources Production Scheduled (PSW) Sequence production within days & shifts Sequence production within days & shifts Dynamically Configurable Structure Dynamically Configurable Structure Dynamically build multi-views to sequence between resources Dynamically build multi-views to sequence between resources Production Scheduled (Base) Multi-Op management Multi-Op management Integrated Component Availability Check Integrated Component Availability Check Production Scheduled (Base) Multi-Op management Multi-Op management Integrated Component Availability Check Integrated Component Availability Check Production Dispatched (PSW) Multi-Select Multi-Select Auto Release Auto Release Export Dispatch List To Excel Export Dispatch List To Excel(MSW) Export Schedule To Excel Export Schedule To Excel Production Dispatched (PSW) Multi-Select Multi-Select Auto Release Auto Release Export Dispatch List To Excel Export Dispatch List To Excel(MSW) Export Schedule To Excel Export Schedule To Excel Production Dispatched (Base) Integrated Component Availability Check Integrated Component Availability Check Integrated Single & Multi WO Print Integrated Single & Multi WO Print View only security for shop floor personnel View only security for shop floor personnel Production Dispatched (Base) Integrated Component Availability Check Integrated Component Availability Check Integrated Single & Multi WO Print Integrated Single & Multi WO Print View only security for shop floor personnel View only security for shop floor personnel Production Reported (PSW) (MSW) Monitor activity with visual completion indicators Monitor activity with visual completion indicators Production Reported (PSW) (MSW) Monitor activity with visual completion indicators Monitor activity with visual completion indicators Production Reported (Base) Monitor WIP of production order Monitor WIP of production order Monitor WIP of operations Monitor WIP of operations Monitor WIP of production cum Monitor WIP of production cum Production Reported (Base) Monitor WIP of production order Monitor WIP of production order Monitor WIP of operations Monitor WIP of operations Monitor WIP of production cum Monitor WIP of production cum MRP MSW PSW Base CAC 9

Cascade Engineering Case Study QAD Planning and Scheduling Workbenches 10

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 Customer: Cascade Engineering QAD Planning and Scheduling Workbenches 11

Product Lines 12 QAD Planning and Scheduling Workbenches

Scheduling thousands of different manufactured items at 5 plants Some items built at one plant and used at another Schedule firm for 1 – 7 days, leading to frequent changes Some customers provide forecasts, some don’t Lot of screens and reports to go through Difficult to see open capacity Integration with in-house shop floor system Cascade Challenges QAD Planning and Scheduling Workbenches Consequences: 1. Lots of time spent wading through reports/screens 2. High level of scheduler frustration 3. Unnecessary scheduling errors 13

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 days 7 day firm schedule Scheduling Carts – New Orders QAD Planning and Scheduling Workbenches 14

Scheduling New Orders - Before QAD Planning and Scheduling Workbenches 15 Repeat entire process (1-6) for cart lids 1. Run MRP Detail Report Scan for unscheduled orders 2. Print Press Schedules 5-7 presses Find capacity Group like colors 3. Add Parts To Repetitive Schedule Maint. Enter part #, site production line, start date, qty 4. Schedule Explosion or Selective MRP Schedule updates auto loaded to shop floor 5. Simulated Picklist Item Check Check for component shortages 6. Update shop floor system Add run sequence and SF comments

Scheduling New Orders - After QAD Planning and Scheduling Workbenches 1. Look for red or yellow colored items and cells on the MSW2. Look for a day with open capacity 16

Scheduling New Orders - After QAD Planning and Scheduling Workbenches 3. Key in quantity on appropriate day4. Visual verification of remaining capacity5. Enter in comments 17

Scheduling New Orders - After QAD Planning and Scheduling Workbenches 6. Sequence production orders7. Component availability check 18

Causes: -Downtime -Component/lid availability -Change in priorities Remember, press schedules generally loaded out days Scheduling Carts – Changes to Schedule QAD Planning and Scheduling Workbenches 19

Repeat entire process (1-5) for cart lids Changes To Schedule - Before QAD Planning and Scheduling Workbenches Print Press Schedules 5-7 presses Find open capacity 2. Run MRP Detail Report What will be late if work pushed back? 3. Manipulate Press Schedules Move work to another press? 4. Change Schedule in Repetitive Schedule Maint Enter part #, site, production line, start date, qty 5. Print press schedules and verify Did I enter everything properly?

Changes To Schedule - After QAD Planning and Scheduling Workbenches 1. Detailed press schedule visible and changeable with drag and drop on PSW 21

Changes To Schedule – After QAD Planning and Scheduling Workbenches 2. Summary schedule visible and changeable on MSW3. What will be late if I push back? – Demand Details Tab4. Do I try to move to another press? – Multiple press schedule visibility 22

Changes To Schedule - After QAD Planning and Scheduling Workbenches 5. Change Schedule – Key quantity on appropriate day6. Visual verification of remaining capacity 23

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 Benefits QAD Planning and Scheduling Workbenches 24

Currently live – 1 location -Rollout – additional 4 USA plants Target – August 2011 Implementation Plans QAD Planning and Scheduling Workbenches 25

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 and test the integration points.NetUI: new element for us Lessons Learned QAD Planning and Scheduling Workbenches 26

MFG Planning & Execution Synchronization Role-Based Manufacturing Browse Collections 27

Purchase Direct Materials Planning and Scheduling Process Support 28

Monitor Material Shortages Planning and Scheduling Process Support 29

Release Production Orders Planning and Scheduling Process Support 30

Manage Materials Planning and Scheduling Process Support 31

Availability & Roadmap QAD Planning and Scheduling Workbenches 32

Availability -Part of core EE as per EE Tied to QAD Maintenance -Add-on for eB2.1 SP4 through 2010 SE Tied to QAD Maintenance.Net Minimum Progress Requirements: -OE10.1C04, OE10.2A02, OE10.2B Documentation -support.qad.com User Guide Administration Guide Training Guide Installation Guide – eB2.1/SE only - Solutions – QAD Manufacturing -Product Data Sheets Planning and Scheduling Workbenches Data Sheet Availability and Documentation QAD Planning and Scheduling Workbenches 33

Workbench enhancements Operational based scheduling Finite capacity scheduling Roadmap QAD Planning and Scheduling Workbenches 34

Summary QAD Planning and Scheduling Workbenches 35

Reduce planning and scheduling time and complexity Compress manufacturing response Provide ability to create effective plans and schedules Enable to be proactive Planning and Scheduling WBs Value QAD Planning and Scheduling Workbenches 36

Everyone working of the same data set A “workbench” created for each role to perform their key daily tasks Browse Collections Value QAD Planning and Scheduling Workbenches 37

Metrics Affected QAD Planning and Scheduling Workbenches 38 ProcessBenefitValue Single screen visibility to detailed load vs. capacity, QOH, demand & supply data Significant reduction in planning/scheduling time Reduced lead times Improved customer service -70 to 75% -5 to 10% 5 to 10% Schedule production for intermediate and final assemblies on production lines directly from customer demand Maximize throughput to maintain minimum finished goods and work in process inventory Improve customer service 10% to 30% Enables load balancing against available capacity and highlights imbalances Improved resource utilization Improved customer service 10 to 20% 5 to 10% Simulation capabilities with sub- assembly and purchased item material checking capabilities Reduce production disruptions due to material shortages Reduce inventory -10% to 30% -10 to 25% Transportation planning Truck load plans with supplier Reduce transportation costs -5% to 20%

Best Products and Services Category - Solutions for Manufacturing Award Winning Application 39

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41 Chris Loerch: Carianne Nieuwstraten: Questions & Answers QAD Planning and Scheduling Workbenches

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