automated data collection at multi-site mfg/pro implementations
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OverviewPremise: – A fully integrated, real-time automated data
collection solution:• Is essential for multi-site implementations• Yields a very high benefit level
Evidence:– GKN Driveline and Eagle Consulting and
Development will use GKN’s US implementation to demonstrate their strategic approach to multi-site implementation and how that approach yielded specific benefits
High-Level Goals and BenefitsGKN wished to:– Build a sophisticated, inter-related network of
sites that could transfer materials and components 24 hours a day
– Track each transfer, in real time, as the sites “feed” one another
– Use offsite warehouse facilities to monitor the movement of material into the manufacturing sites
– Meet the stringent requirements of Honda and other high-profile automakers, including Just-In-Time product delivery.
The Multi-Site / Multinational RolloutUnique challenges and requirements– Maintain seamless connection between sites – Transfer materials between sites efficiently– Establish and maintain high levels of visibility
into the network of sites– Address differences in local equipment,
process and people
– Meet varying end-customer requirements
About GKNCompany background– World’s leading producer of automotive
driveline components– A global tier-one supplier– 21,000 people at 49 locations in 31 countries.
Power Transfer Unit
GKN Driveline's PTUs are compact, lightweight, have excellent NVH (noise, vibration, harshness) characteristics. This makes them a popular choice in a large range of applications.
Copyright GKN plc
About GKNAn industry leader– Closely involved with many key milestones in
automotive history. A recent example:• Jan 2006 announcement: Vehicle makers plan to
introduce breakthrough technology from GKN Driveline that provides lighter driveshaft components, improved fuel economy and better overall vehicle performance… including reduction in driveline noise, vibration and harshness.
• This has been described as the first major change in constant-velocity-joint (CVJ) technology in more than 70 years
• GKN Driveline currently produces more than 95 million CVJs per year
GKN’s Requirements External– Meet automaker requirements (e.g., Honda)– Meet end customer requirements
• GM, Ford, Honda and others
Internal– Replace existing automated data collection
system and see significant improvements
– Increase the number of transactions captured in real time
– Reduce the number of disconnected systems
Achieve savings– Eliminate waste
Increase productivity– Gain access to more
accurate reporting Improve accuracy– Reduce human intervention– Establish consistent process
across sites Leverage QAD MFG/PRO
capabilities
GKN’s Expected Gains
Copyright GKN plc
Why chooseEagle’s solution:
RF Express™ for
MFG/PRO
RF Express for MFG/PRO:– Provides a seamless, plug-and-play integration
with QAD MFG/PRO– Is an online, real-time, PROGRESS-based
automated data collection and bar coding solution
– Enables all Eagle customers to enjoy the benefits of simplified data entry, portable terminals, barcode scanning/labeling, as well as integrated scale weight transactions and the ability to print portable bar code labels
– Makes it possible to configure functionality on a site-specific basis
Technical considerations
RF Express for MFG/PRO:– Does not require any side databases or
separate server platform • multi-site implementations do not require
a separate server for each physical site– Operates in Linux, Windows and UNIX
environments– Supports both Progress and Oracle databases– Calls QAD MFG/PRO edit and update routines
to provide real-time data checking with enhanced functionality
Technical considerations (continued)
RF Express for MFG/PRO:– Supports a wide array of
devices, including:• RF handheld networks
– IEEE 802.11BG Direct Sequence– Fixed shop floor stations with
laser scanners
• RFID tags• Fixed RF printers• Portable RF printers• Scales• Thermal transfer printers• Bumpy bar codes
Technical considerations (continued)
Copyright GKN plc
Less hardware and software are required because RF Express for MFG/PRO uses the existing database and existing server
Reduced database/server ongoing maintenance
Simplified database control: QAD MFG/PRO and RF Express for MFG/PRO work together
Cost considerations
Eagle has provided solutions to the QAD MFG/PRO community since 1992
Eagle’s solution is currently installed at 800 customers and over 3,000 sites worldwide
Eagle is used only by QAD MFG/PRO customers, so all installations are also QAD MFG/PRO installations
Eagle’s customer list includes Fortune 500 companies worldwide in every industry served by QAD
Eagle’s status as a Honda-approved solution provider, as well as its experience with FDA compliance issues, enables Eagle to add value in addressing industry-specific requirements
Industry Acceptance and Usage
Eagle consistently achieves Excellent customer ratings not only on its product, but on its responsiveness, support and service
For specific customer comments, visit Eagle’s booth for a copy of What Our Customers Say
Customer Satisfaction
Key Process Points –
RF Express for MFG/PRO
Scope and Project Plan Initial onsite analysis July 2004
– Primary implementation site identified– Site-specific requirements identified– Initial software pilot environment setup completed
Training/piloting activities Sept 2004-Feb 2005 per GKN timeline– Honda EDI/label testing– Test 50+ other ship-scenarios – GKN brought key representatives from each site
to the “training house”
Timelines: GKN’s and Eagle’sGo Live February 2005---All sites– Key support from the primary site
Implementation Nuts and Bolts
RF Express for
MFG/PRO
Keep the transactions simpleMaintain Pallet/Container Reference
numberCapture transactions in real time
Eagle User Requirements
Inventory Management ModuleAdvanced RepetitiveEnhanced ShippingWarehouse Management
Eagle Transactions
PO ReceiptPallet MoveComponent scrap
Inventory Management Module
Kanban Backflush with Container Label Create
Backflush with Multiple Container Label Create
Advanced Repetitive Module
Load Truck – With automatic additional container item add
Verify Load
Enhanced Shipping Module
Pallet Distribution Order ShipPallet Distribution Order Receipt
Warehouse Management Module
fulfills the request using the Pallet Distribution Order Ship transaction
Eagle Transactions Linking the Sites
Alamance SiteRoxboro Site
places an intersite request via QAD MFG/PRO
receives the product via Pallet Distribution Order Receipt transaction
moves the components to the work center location via Pallet Move/Unlink
produces a component to be used in Roxboro using backflush transaction
Maintain existing Intermec Trakker Antares handheld terminals & RF backbone
Maintain existing Intermec printers Maintain “rolling” portable Intermec
printers
Hardware
Effective use of pilot scenarios– Pilot scenarios represented real-world
activities– Users caught on very quickly– Users were able to articulate
the site-specific requirements– GKN used RF Express for MFG/PRO
extensively to deliver training between Eagle visits
Multiple pilots lead to a smooth go-live
Implementation and Synergy
Introduced in transaction section – Distribution orders
Critical to GKN business– Uses Kanban system to drive interplant
requisitions– Requisitions are fulfilled using Pallet
Distribution Order Ship Transaction– Product is received 24 hours/day using Pallet
Distribution Order Receipt Transaction
Provides best input to MRP
Usage Between Plants
Multi-site simultaneous go-live was critical to success
Training must be thorough at all sitesSystem stress test was very importantAround-the-clock support quickly
addressed issues – System experts were available to the users
Lessons Learned
Previous sites– Asia
This implementation– North America
Future (now!)– Europe– South America
Global Rollout
John MalvasoIS/IT Manager for Business
ApplicationsGKN Driveline North America (DNA). 6400 Durham RoadTimberlake, NC 27583 USA+1.336.364.6449+1.248.364.7681 (fax)[email protected] www.gkndriveline.com
Contact Information
Jim MiceliSenior Project ManagerEagle Consulting and
Development135 Kinnelon Road, Suite 204Kinnelon, NJ 07405+1.973.838.5006+1.973.492.2758 (fax)[email protected] www.eaglecondev.com
RF Express™ for MFG/PRO is a trademark of Eagle Consulting and Development.“QAD” is a registered trademark of QAD Inc.
All other products or Company names herein may be trademarks of their respective owners.