Automated Shop Floor Data Collection

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Automated Shop Floor Data Collection

• Supporting business processes and eliminating the
  cost of human error in the data collection process

• Michael Olson
• Director of IT, Continental Structural Plastics

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Presentation Agenda

• Automated Shop Floor Data Collection

• About CSP
• Production reporting
• Semi-finished inventory Out of Control
• Need better inventory record accuracy
• Current processes do not work
• Who owns the data?
• How did we do ?
• Questions

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About Continental Structural Plastics (CSP)

• Automated Shop Floor Data Collection

• Continental Structural Plastics, Inc. is a
  privately held company, founded in 1982 and based
  in Troy, Michigan with production facilities in
  Sarepta, Louisiana Huntington, Indiana, and Ohio.

The company manufactures structural plastic
components, bumper beam reinforcements, rocker
covers, oil pans, stamped steel seat frames, and
underbody shields, as well as outer body panels
(e.g., Corvette). It also offers composite seat
bases, engine oil sumps, and composite sunshade
substrates and molders of glass-mat
thermoplastic composites, as well as
long-glass-fibre-reinforced thermoplastic and
direct-LFT composites.
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About Continental Structural Plastics (CSP)

• Automated Shop Floor Data Collection

• Markets
• Automotive, Heavy truck, Agricultural, HVAC,
  Building Construction, Materials Sales
  Technologies
• Technologies
• Thermoplastics, Natural Fiber Composites, Sheet
  Molding Compound, Low Pressure Thermoplastic
  Composites

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Where to Begin

• Automated Shop Floor Data Collection

• Define the issue
• How do others do it?
• Timeliness of production feedback
• Are we alone?
• How do we know?
• Clear understanding of process
• Inventory is highly inaccurate
• Batch process feedback
• What tools do I have available?
• QAD System
• Eagle RF Express for QAD Enterprise Applications

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What Tools Do I Have?

• Automated Shop Floor Data Collection

• Why Eagle?
• We needed to be able to handle multi-site
  differences and achieve a very high degree of
  accuracy Eagles large installed base indicated
  that they could do it
• An example of an important capability was Eagles
  rfvalues table, which enabled us to set up each
  site individually without any custom code.

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Where to Start

• Automated Shop Floor Data Collection

• What is Root Cause?
• Cycle count more
• Physical inventory
• What is learned from current reporting
• Can be text and screenshots or related graphics
• Cannot be us, Darn System!
• Could be them
• Too complex
• I dont have time

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Where to Start

• Automated Shop Floor Data Collection

• Reported twice, thrice
• What is learned from current reporting?
• How do I keep from double dipping?
• Scrap
• Rework
• Rejects
• Cannot be us, Darn System!
• Could be them
• Who is currently responsible?
• Should they be?
• Write it down!

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Lets Draw a Picture

• Automated Shop Floor Data Collection

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How to Implement

• Automated Shop Floor Data Collection

• Eagle BKF or BKN
• How do I measure the process ?
• Is existing data OK?
• Big Bang or Small Bite
• Pilot and Model
• Auto vs. Manual / Exceptions
• Write it Down / Document
• Budget required
• S/W
• H/W

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Sample Forms / Screens

• Automated Shop Floor Data Collection

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Sample Forms / Screens

• Automated Shop Floor Data Collection

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Sample Forms / Screens

• Automated Shop Floor Data Collection

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Sample Forms / Screens

• Automated Shop Floor Data Collection

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Sample Forms / Screens

• Automated Shop Floor Data Collection

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Summary How Did We Do?

• Automated Shop Floor Data Collection

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How Did We Do?

• Automated Shop Floor Data Collection

• Sites require different process models
• Gather feedback and measure, then measure some
  more
• Inventory Integrity Improved 95
• Few Surprises at physical or cycle count
• Exceptions are best performed in full screen QAD

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Next Steps

• Automated Shop Floor Data Collection

• Roll out to all sites
• Lot Control

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CSP Contact

• Automated Shop Floor Data Collection

• Mike Olson
• Director IT
• 755 W. Big Beaver Road, Suite 700
• Troy, Michigan   48084
• 248 823 5665  Office
• mike.olson_at_cspplastics.com

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Eagle Contacts

• Automated Shop Floor Data Collection

• Corporate / The Americas
• Bill Paone, Executive VP, Sales and Marketing
• 1.973.838.5006 Ext 119
• bpaone_at_eaglecondev.com
• Europe Africa
• Robert Freeman, Director, Eagle-Europe
• 44(0) 1451 812266
• rmf_at_eagle-europe.com
• Asia Pacific
• Ian Watts, Director, Eagle Asia Pacific
• 65-6827-9091
• iwatts_at_eaglecondev.com

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Questions Answers?

• Automated Shop Floor Data Collection