cistech xa user conference scott kadak, division information systems implementing shop floor...

CISTECH XA User Conference

Scott Kadak, Division Information Systems

Implementing Shop Floor Reporting at Schrader Bridgeport



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



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



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



Why Implement Shop Floor Reporting

• Shop floor data is fundamental for:– Inventory control– Scheduling– Material Planning– Costing

• WIP was always a “black hole”



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



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



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



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)



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



Current Environment• Standard touch screen setup



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




• 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




• Scrap Reporting– During Job Off (SM)

– Scrap Component (SC)

• Operation complete transaction• Manufacturing order complete transaction



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




• 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




• 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.



Paper-Less Enhancements• Supervisor Report



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

cistech xa user conference scott kadak, division information systems implementing shop floor...

Documents

xa release

shop floor reporting

shop floor supervisors

shop floor activity

needed slide

iseries slide

floor associates

transaction reporting