lt success story presentation r2
TRANSCRIPT
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SUCCESS STORY OF WRENCH IMPLEMENTATIONAT
Larsen & Toubro LimitedMachinery & Industrial Products Division
LTM Business Unit, Chennai .
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LTM Chronology
1972 Established as a JV between L & T Limited and McNeil Akron Inc, USA under the name L&T-McNeil Limited
1974 Commenced Production of Tyre Curing Presses
1988 Technical Collaboration with Mitsubishi for Tyre Building Machines & Bias Cutters and with Demag for Plastics injection moulding machines
1995 L&T buys the complete shares of McNeil Akron Inc in L&T- McNeilLimited and forms a wholly owned business unit of L&T for Rubber & Plastics machineries
2001 JV with Demag for Plastics machinery
2003 Collaboration with Kobe for manufacture of latest range of Curex S1
series Hydraulic Tyre Curing Presses
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Growth
Rs. Million
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Mechanical Tyre Curing P ressesFrom 24" to 104"
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Some of our major CustomersSome of our major Customers
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LTM presenc e in t he Wor ld ...
CHINA
EGYPT
U.K
FINLAND
ITALY
KENYA MALAYSIA
MOROCCO
NEPAL
SRILANKA
SYRIA
TANZANIA
THAILANDTURKEY
VIETNAM
ARGENTINA
BRAZIL
CHILE
CUBA
ECUADOR
VENEZUELA
INDIA
SPAIN
INDONAESIA
PHILIPPINES
ISRAEL
SOUTH AFRICA
USA
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PRODUCT DEVELOPMENT PROCESSPRODUCT DEVELOPMENT PROCESS
NEW PRODUCTS
PRODUCTS VARIANTS TO CUSTOMER NEEDSRESULTING IN
MAJOR DESIGN MODIFICATIONS TO EXISTINGPRODUCTS
MINOR MODIFICATIONS
PRODUCT CONFIGURATION TO MEET CUSTOMER
REQUIREMENTS
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PEOCESS FLOW FOR PRODUCT DEVELOPMENT
procedure thru PLM
engg team on review
Design Department
Sales Dept.
StartReceive
Request forChange
Evaluate andAnalyseChange
Initiate ECOWorkflow in
Wrench
ECOApproved?
Rework
Release of Changed BOM/ Drawings/Specs to Other
departmentsEND
ECO PROCESS FLOW
Yes
No
ReceiveCustomerEnquiryDetails
from Sales
Follow1. Enquiry to Quote2. Quote to Sales
Order
Prepare TentativeBOM of Critical Sub-
Assemblies andProvide details for
Estimation &Quotation purpose to
Sales Dept.
Start
Design Department
Receive SalesOrder with
detailed Specs
Start designDesgin Activityas per ISO
CreateDrawings &
BOMs
Design Outputreview withconcurrent
Release ofBOM to ERPthru PLM
FinalDrawings &BOMs based
Layout DrawingApproval toCustomer ?
TechnicalReview
meeting Toconfirm Tech
Specs andcompatibility
Modify
Release ofDrawings formanufacturingthru PLM
END
PrepareEquipmentSafety (CE)file wherever
required
No
Yes
Design Department
Design Department Sales/Design Dept.
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Problems Faced before WRENCH implementation
Total dependency on individuals.
25 to 30% time spent for searching for data.
Mismatch of revision numbers between ERP data and actual drawings
No system to prevent usage of drawings to old revisions.
Delay in issue of drawing prints due to manual processs and uncontrolled
No link between drawings and BOMs and manual entry of BOM for MRP
No control over multiple copies of the same drawing.
Lack of security on intellectual data being copied out.
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Problems Faced before WRENCH implementation
Errors in product configuration due to manual process and time consuming.
No collaboration among cross functional departments.
No sharing of massive volume of digital product data available with differentdepartments like Engg,Marketing,Purchase,Manufacturing,Service,etc.
Poor visualization for the users as there was no tools to access the3D solid models created by design department.
Product history not captured and maintained systematically.
Most of the learnings /design calculations during product development lost.
Change management was manual , slow and not communicated to endusers well in time
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Problems Faced before WRENCH implementation
To overcome these problems many adhoc procedures/
systems were adopted likePrint request program.
Centralised storage of drawings with defined File namingprocedure.
View access for cross functional departments for drawingsstored in R&D server.
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VISION for an Ideal Design Environment
A l l d o
c u m e n t s
i n e l e c
t r o n i c
f o r m
3 D s o l i d
m o d e l i n g
c o n c e p t
Asse m b l y based
o n co ns t ra i n ts
As s o c i a t i o n o f D e s i g n d a t a / F E A w i t h p a r t s
C a l c u l a t i o n s /
Ideal
Design EnvironmentHow we design in future?
3 D s o l i d d i r e c t l y a s s o c i a t e d w i t h 2 D
V ie w i ng a nd
P r i n t i ng fac i l i t ies
a t use r e nd
C a l c u l a t i o n s a s s o c i a t e d w i t h As s e m b l i e s
Q ua l i t y P la nassoc ia ted w i t h
Asse m b l ies
C ha nges
assoc ia ted w i t h
3 D Asse m b l iesAut o c o st i ng a t c o nc e p t st a g e
C o n c u r r e n t E n g i n e e r i n g i n
t h e m a i n s t r e a m S c h e d u l e f o r p r o t o t y p e a t c o n c e p t
BO Msassoc ia ted w i t h
Asse m b l ies
Online costing of new tools
S i n g l e w i n d o w a c c e s s
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Challenges faced
Brain storming to list out the requirements for anideal single window access system for design.
Evaluation of available softwares to short listbased on the following priorities
Meeting the requirements as per the vision statement Seamless interface with the existing MRP-II system Customisation skills to follow good practices being followed Cost of implementation and maintenance Possibility for future upgrades / addition of new modules
Conversion of Legacy data built over many years to digital data.
Understanding the existing MRP-II system and interfacing.
Training and smooth change over to the new system.
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Benefits after implementation of WRENCH
50% Faster product development due to on-line availability ofdesign data, re-use of existing variants& flexible search capabilities
15 times faster product configuration due to BOM variant concept Single window access for design engineers & Immediate access toJDEdwards ERP without consuming the license of ERP package
No manual keying-in and duplication of engineering data into ERP
On-line access to the latest drawings with defined security
Concurrent engineering during design stage.
40% Reduction in number of drawing prints
Automatic work flow management for Draw/Check and Approval
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Benefits after implementation of WRENCH
Automatic print management
Complete security for design data in server
Faster change management.
Linking of Design calculations,FEA, Moms,check sheets, test
data & customer feed back to part master/work orders. Possibility to view and mark 200+ file formats
Sharing of information between departments
Better visualisation of the part by users by viewing the solidmodels
Quick review of project status with color codings of status
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WHAT NEXT
1. Extend access to Sales and branch offices.
2. Non conformance management.3. Provide online spare part catalogue.
4. Extend product data to vendors with restrictedaccess.
5. Online capture of customer feedback on products.
6. Extract knowledge from real time ECO & NC data.
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Thank You
Have a nice day !