Automated Shop Floor Data Collection

Automated Shop Floor Data CollectionMichael OlsonDirector of IT, Continental Structural Plastics

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

• 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

Presentation Agenda

Automated Shop Floor Data Collection

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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.

About Continental Structural Plastics (CSP)


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.

Markets• Automotive, Heavy truck, Agricultural,

HVAC, Building Construction, Materials Sales Technologies

Technologies• Thermoplastics, Natural Fiber Composites,

Sheet Molding Compound, Low Pressure Thermoplastic Composites

About Continental Structural Plastics (CSP)


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• 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

Where to Begin


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

What Tools Do I Have?


• 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 don’t have time

Where to Start


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• 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!

Where to Start


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• 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

How to Implement


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Summary – How Did We Do?


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• 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

How Did We Do?


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• Roll out to all sites• Lot Control

Next Steps


Mike OlsonDirector IT755 W. Big Beaver Road, Suite 700Troy, Michigan 48084248 823 5665 [email protected]

CSP Contact


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Corporate / The AmericasBill Paone, Executive VP, Sales and Marketing+1.973.838.5006 Ext [email protected]

Europe & AfricaRobert Freeman, Director, Eagle-Europe+44(0) 1451 [email protected]

Asia PacificIan Watts, Director, Eagle Asia [email protected]

Eagle Contacts


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Questions & Answers?


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Documents

Automated Shop Floor Data Collection