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

2. 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

3. 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

4. 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

5. 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

6. 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

7. 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

8. 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

9. 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

10. 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

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

12. 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

13. 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

14. 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

15. 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

16. 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

17. 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

18. Paper-Less Enhancements
Scott Kadak,
Division Information Systems

19. Paper-Less Enhancements
Scott Kadak,
Division Information Systems

20. Paper-Less Enhancements
Scott Kadak,
Division Information Systems

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

22. 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