1. 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 19th

2. Agenda What is Zehnder Rittling
Introduction – Visual Manufacturing Solution
System Architecture & Demonstration – Visual Manufacturing Solution
Question & Answer on Visual Manufacturing Solution
Introduction – Quality Feedback System
System Architecture & Demonstration – Quality Feedback System
Question & Answer on Quality Feedback System
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

3. Zehnder Rittling Company Summary Zehnder Rittling Organization
150 employee subsidiary of Zehnder Group, a $700M 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

4. Zehnder Rittling Systems Summary QAD SE 2010
Located at our sister company in the Netherlands
Implemented in 2009 at our site
Factivity 3.2L
Located in our Buffalo, NY facility
Implemented in 2009
Synexus Order Entry Configurator
Custom developed solution hosted at a 3rd party in the Netherlands
MS SharePoint Foundation 2010
QAD
Work Order Release
Sales Order & Item Creation
Labor Feedback
Work Order Receipt
&
Shipment Transactions
Sales Order Updates
&
Factivity
Synexus
Link to Quality
Feedback System
SharePoint
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

5. Agenda What is Zehnder Rittling
Introduction – Visual Manufacturing Solution
System Architecture & Demonstration – Visual Manufacturing Solution
Question & Answer on Visual Manufacturing Solution
Introduction – Quality Feedback System
System Architecture & Demonstration – Quality Feedback System
Question & Answer on Quality Feedback System
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

6. 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

7. 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

8. Agenda What is Zehnder Rittling
Introduction – Visual Manufacturing Solution
System Architecture & Demonstration – Visual Manufacturing Solution
Question & Answer on Visual Manufacturing Solution
Introduction – Quality Feedback System
System Architecture & Demonstration – Quality Feedback System
Question & Answer on Quality Feedback System
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

9. 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 eDrawings
Provides a customizable terminal interface to show and send CAM programs via a serial interface
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

10. 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, eDrawings 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

11. 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

12. Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
Example Case (Configurator & QAD Setup)
We have parent item 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

13. Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
Example Case (Configurator & QAD Setup)
In our case I will demonstrate one SolidWorks model 11D A attached to the parent item through the configurator, and one sub assembly A and it’s associated documents, 11D A, 11P A.
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

14. 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 11D and 11P 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.
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

15. Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
Example Case (Factivity Display of Documents)
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

16. Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
Example Case (Factivity Display of Documents)
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

17. Zehnder Rittling – Visual Manufacturing Solution
System Demonstration
Example Case (Factivity Display of Documents)
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

18. 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

19. Agenda What is Zehnder Rittling
Introduction – Visual Manufacturing Solution
System Architecture & Demonstration – Visual Manufacturing Solution
Question & Answer on Visual Manufacturing Solution
Introduction – Quality Feedback System
System Architecture & Demonstration – Quality Feedback System
Question & Answer on Quality Feedback System
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

20. Agenda What is Zehnder Rittling
Introduction – Visual Manufacturing Solution
System Architecture & Demonstration – Visual Manufacturing Solution
Question & Answer on Visual Manufacturing Solution
Introduction – Quality Feedback System
System Architecture & Demonstration – Quality Feedback System
Question & Answer on Quality Feedback System
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

21. Zehnder Rittling – Quality Feedback System
Introduction
Quality Feedback System Summary
A MS SharePoint 2010 Foundation based solution that is launched via Factivity to provide operators a way to initiate a quality remediation process instantly from their terminal
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

22. 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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

23. 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 SharePoint list can be done in less than a day by an intermediate SharePoint 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 SharePoint site using the same modal IE window that was used for our Visual Manufacturing solution
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

24. Agenda What is Zehnder Rittling
Introduction – Visual Manufacturing Solution
System Architecture & Demonstration – Visual Manufacturing Solution
Question & Answer on Visual Manufacturing Solution
Introduction – Quality Feedback System
System Architecture & Demonstration – Quality Feedback System
Question & Answer on Quality Feedback System
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

25. Zehnder Rittling – Quality Feedback System
System Architecture
MS SharePoint 2010 Foundation
Uses a SharePoint survey to provide branching logic to help guide the production floor operators to the appropriate result
* Limitations of SharePoint surveys
Uses simple SharePoint work flows to distribute the information and kick off the quality defect resolution process
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

26. Zehnder Rittling – Quality Feedback System
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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

27. Zehnder Rittling – Quality Feedback System
System Demonstration
Our Environment
In this case we will show a quick example of a problem with the product paint quality
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

28. Zehnder Rittling – Quality Feedback System
System Demonstration
Our Environment
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

29. Zehnder Rittling – Quality Feedback System
System Demonstration
Our Environment
Once the submission is completed the Quality Feedback record is sent by to the Quality Control department for review
After review to ensure that the issue is valid the Quality Control technician initiates a rework work order or delivers the product back to a workcenter for additional work to be done
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

30. Zehnder Rittling – Quality Feedback System
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
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018

31. Agenda What is Zehnder Rittling
Introduction – Visual Manufacturing Solution
System Architecture & Demonstration – Visual Manufacturing Solution
Question & Answer on Visual Manufacturing Solution
Introduction – Quality Feedback System
System Architecture & Demonstration – Quality Feedback System
Question & Answer on Quality Feedback System
Zehnder Rittling – Visual Manufacturing & Quality Feedback System
9/20/2018