Production Report System Improvement ????????

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Production Report System Improvement ????????

• Members Michael Brown,
• Gabriel Baldwin,
• Ji Wu,
• Mingyuan Gao,
• Liang Wang

Company Saint-Gobain Abrasives Shanghai WPI
Advisor Professor Rong HUST Advisor Professor
Gao, Liu, Dr. Qiu Company Sponsor Mr. Youyue Tong
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About Saint-Gobain - ?????

• Founded in 1665
• The materials mega-group
• Flat glass ????
• Abrasives ??
• Ceramics ??
• Plastics ??
• Packaging ??
• Building materials ????
• Acquisition of Worcester based Norton Company in
  1990
• Entrance into the Abrasives Field

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Saint-Gobain Abrasives Co., Ltd Shanghai. -
?????????????

• Established in 1994
• 800 employees at two plants
• Minhang Economic Development Zone
• Dongguan, South China
• Some of the manufactured products

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ERP and SAP

• Enterprise Resource Planning
• Utilizes Information Technology to collect and
  store all information in a business process, and
  analyze it to make better decisions
• Many different ERP packages which tailor their
  software to different needs of businesses
• SAP R/3 is the most popular ERP program
• Has a powerful manufacturing management suite
• In use by St. Gobain

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Problem -??

• ERP SAP data is poorly utilized
• SAP??????????
• Manual data analysis
• Time consuming 2 hours a day
• Limited depth of analysis potential
• Difficulties coping with changing supply and
  demand
• Limited insight into where to apply lean
  manufacturing principles

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Mission - ??

• Mission Using Microsoft Access, to help St.
  Gobain Shanghai better utilize its ERP data
• This will aid in Production Indicators Planning
• ????Access?????????????ERP ????

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What is a database????????

• Information Technology Tool
• Stores information
• Allows information input
• Provides a user interface
• View information or data
• Reports
• Graphs
• Summaries
• Microsoft Access

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Project Schedule - ?????
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Objectives ????

• Identify Problem - ????
• Determine problems in the existing production
  report system
• Determine Needs - ????
• Identify the current needs of St. Gobain Shanghai
• Gain Necessary Skills ????
• To solve the identified problem and fulfill the
  company needs
• Map Data Structure - ???????
• Determine the best way to store data within the
  database
• Check with SG to find any mistakes or omissions
• Build Test the Database System - ?????
• Provide written documentation

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Problem Identification - ????
Objective One

• To improve the utilization of ERP SAP data
• ????????ERP SAP ??
• Solution
• Create new database to fit the unique needs of
  Shanghai
• Cannot easily convert UK System

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Determine Problems in UK Database - ??????????

• UK Access database is very complex
• ??Access???????
• No relationships between UK tables
• Excess use of queries to replace links between
  tables
• Queries utilize data that Shanghai does not use
• Different product lines have different properties
• Forms/menus will be very different
• Different products will need different options
• Inefficient layout
• UK Reports do not contain all requested Shanghai
  requirements for content

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St. Gobains Needs???????
Objective Two

• Reduce employees time spent processing ERP SAP
  data
• ??????????
• Creation of database similar to UK system
• ???????????????
• With reports, graphs, and summaries
• Different set of products
• Addition of fields to reports
• Size, Process stage

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Skills Needed ????
Objective Three

• Building database
• Microsoft Access
• Detailed knowledge of object types
• Relationships between objects
• Simple Visual Basic Language
• SQL

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Map Data Structure???????
Objective Four

• Systematically listed all components and
  relationships between each of the objects in UK
  database
• Schematically mapped the relationships of UK
  database objects and data fields on paper

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Understanding Database Relationships - ??????
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Database Objects Overview ???????

• Tables - ?
• Where data is stored
• Queries - ??
• Find, add, edit and delete information from
  tables
• Forms/Menus - ??
• How the user interacts with the database
• Reports - ??
• Visual representation of stored information
• Macros (macro-instruction) - ?

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Build Test Database ?????
Objective Five

• Design database
• Build database
• Test database
• Provide written documentation for database

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Method for Database Design???????

• Utilize mapped UK database to create a new
  database
• Tailored data fields to Shanghais SAP data
• Query/table relationships follow new primary
  fields
• Updated and improved menu layout and content
• Simplified parts of UK system that were
  unnecessarily complex

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Necessary Database Functions???????

• Display reports and graphs of
• Orders
• Paper Loads
• In Process
• Produced
• Rejects
• Weekly and Monthly Summaries
• Input regular data updates

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Building New Database?????????

• Create database objects separately and combine
• Create tables and queries
• Relations
• Create forms and reports
• Integrated with Visual Basic
• Combine forms/reports and tables/queries

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Tables ?

• Link raw data from SAP into database

• UK

• Shanghai

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Queries in UK - ??

• Contains all necessary fields

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Queries in Shanghai - ??

• Functions derive data not provided by Shanghai

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UK Main Menu????????????
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Main Menu for Shanghai Database ??????
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UK Report Example????????????
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Shanghai Report Example????????
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Example Graph ?????
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Testing ??

• Test database
• Run through process cycle repeatedly
• Input data updates
• Produce reports and graphs
• Troubleshoot on companys computer with Shanghai
  employees
• Make any necessary changes and retest

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Documentation - ??????

• Provide written documentation of database
  constructions
• User Manual English and Chinese
• To allow for future expansion and/or changes to
  the database

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And now for a demo????
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Conclusions

• Our project allows Saint-Gobain to utilize its
  ERP SAP data effectively
• Reduce time to process ERP SAP data
• 2 hours -gt less than 30 minutes
• Allows management to see trends and make changes
• Cope with changing supply and demand
• Help to identify problem areas in the
  manufacturing system
• Provides insight into how to apply lean
  manufacturing principles

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More conclusions

• Shanghai could expand this database
• Tracking analysis
• Rejection analysis
• Companys first reaction
• This database system is quite good
• The menu is beautiful and convenient
• The logic of the queries and table design is
  clear and rational
• The data will still need to be confirmed
• Over the next couple weeks
• I believe that it will work correctly

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Acknowledgements

• WPI
• Professor Kevin Rong
• HUST
• Professor Gao Liang
• Professor Liu Shiping
• Dr. Qiu Haobo
• Saint-Gobain
• Mr. Tong Youyue
• Miss. Lv Jing
• Mr. Shen Yijun
• Miss. Tu Zhuoxia

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Questions?