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QAD Training Program Evolution at The Tech Group: Challenges & Solutions

Dive into the journey of QAD training at The Tech Group, overcoming challenges of poor data quality, undefined programs, standardized processes. Explore the shift to a hands-on approach and the impact on ERP functionality.

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QAD Training Program Evolution at The Tech Group: Challenges & Solutions

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  1. QAD TrainingMWUG Slides September 2015 Jackie Das

  2. Intro – Jackie Das • Project Manager at the Tech Group • Finance background • 4 years ago, I was asked to lead a project to upgrade QAD to 2011 SE across all 9 sites. • Since then, worked on QAD training, implementation and improvement projects, and IT projects Tech Group Confidential

  3. The Tech Group • Nine Manufacturing Sites using QAD • 1,000,000 square feet of mfg. space • $275MM in Sales/1,500 employees • A division of West Pharmaceutical Services, • Inc, a $1.4bn company • Competencies: • Product Development • Injection Molding • Contract Assembly • Finished Packaging “A process driven, full service developer and manufacturer of components & devices for the healthcare industry” Tech Group Confidential

  4. Manufacturing Footprint Ireland Michigan Denmark Indiana Pennsylvania Manufacturing Sites Development Centers Arizona (4) Puerto Rico 7 Tech Group Confidential

  5. Markets Served Medical Care Components & Assemblies Ophthalmic, Ambulatory, Surgical Pharmaceutical Devices & Final Packaging Pulmonary & Injectables Diagnostics Components, Kits & Packaging Molecular & Point of Care Consumer Components & Assemblies Personal Care & OTC Packaging Tech Group Confidential

  6. QAD/MfgProUser since 1988 ChUI NetUI Mercury Cyberquery Eagle Version: 2011 SE

  7. Today’s goal • Share with you our training program ‘journey’ at The Tech Group • Review some of the challenges and how we are working through them • Answer your questions Tech Group Confidential

  8. Evolution of QAD training/improvement program 2015 and Beyond Training program continues *No ‘formal’ training* Tech Group Confidential

  9. Problems we faced: • Trust in ERP system/Poor quality data • No defined training program • Business Processes not defined/standardized • No baseline understanding of APICS and ERP concepts • Not using all ERP functionality/working outside the system • Reporting difficulties/visibility across sites • No champion/no strategy • No ‘go to’ for training PEOPLE! PROCESS! PLATFORM! Tech Group Confidential

  10. #1:Trust in the system/Poor quality data • What we were hearing: • “The system won’t allow us to do that…” • “The system is crap….” • “We don’t trust the reports…..” • “ I don’t use MRP because it’s wrong…” “The MRP reports are so long I can’t find what I’m looking for…” • “The inventory balances in the system are off, I’m better off walking the floor to see where my stuff is at” Tech Group Confidential

  11. #1:Trust in the system/Poor quality data • What we did: • Train people on the meaning of the various data fields and how they impact processes and reports. • Week long ‘workshop’ to agree how all the sites would use use key data fields • Began “cleaning up” the data • Examples: • Planning data • Archiving Tech Group Confidential

  12. #2:No defined training program: • What we used to do: Tech Group Confidential

  13. #2:No defined training program: • What we do now: • All new hires go through formal training • Online training videos (learning portal) on SharePoint site Tech Group Confidential

  14. #3:Business Processes not defined/Standardized: Manufacturing is challenging! QAD impacts everything we do and can be confusing.

  15. #3:Processes not defined/standardized • Agreed ‘best practice’ processes across all sites – week long workshop held in 2014 • These form the basis of training Tech Group Confidential

  16. #4:No baseline understanding of APICS and ERP concepts What we had before: • People understand only the transactional piece of their job • No understanding of why their piece is important • People feeling isolated. • Acronyms and terminology not understood Tech Group Confidential

  17. #4:No baseline understanding of APICS and ERP concepts What we have now: • Understanding in the business of how what people do impacts the upstream and downstream processes. Tech Group Confidential

  18. #4: No baseline understanding of APICS and ERP concepts: • Developed a 3 day training (not hands on in QAD) to teach concepts • Lego game to demonstrate: • BOM • Inventory control • MRP • Costing • Forecasting • Variances • Formal APICS training • Plan to take the 3 day training and make it “hands on” Tech Group Confidential

  19. #4: No baseline understanding of APICS and ERP concepts: • Trained over 100 people • Went to all the sites • Measured results – quiz before and after class • Published glossary of terms Tech Group Confidential

  20. #5:Not using all ERP functionality/working outside the system: • What we had before: Tech Group Confidential

  21. #5:Not using all ERP functionality/working outside the system: And th Guessing games Spreadsheet overload Manual Systems

  22. #5:Not using all ERP functionality/working outside the system: • MRP in use at most plants • Planning and Scheduling Workbenches implemented by end of 2015 • Forecasting • GRS (Global Requisitioning System) • EAM (Enterprise Asset Management) • Fixed Asset Module implemented in Europe TRAINING!! Tech Group Confidential

  23. #6:Reporting Difficulties/Visibility across sites • What we had: • Unable to readily access data for consolidated reports • Hunting and pecking for information we needed • Reliance on other people • What we have now • Browses and browse collections • Cyberquery • 60 people across the company trained • Puts the power in their hands Tech Group Confidential

  24. #7 & #8:No Champion/No Strategy - No “go to” for Training • ERP Excellence Director • ERP Excellence Team: • Project Manager • IT Business Analyst • Supported by top management • Expected to deliver measurable results • Central resource for training • Coordinated approach to training Tech Group Confidential

  25. Time Frame Alert!! • No quick fix! • No easy button • Not a one year project, not a 5 year project…. • Multi year project Tech Group Confidential

  26. Final words….Lessons learned • Remember the 3 P’s – People, Process, Platform • Get a Corporate Sponsor(s) • Training doesn’t belong in IT • Peer pressure is a great thing! • Right people/right time – MSW/PSW is a case in point • Start with the end in mind • Make training interesting • Keep the momentum going • Don’t get discouraged! Tech Group Confidential

  27. Questions Tech Group Confidential

  28. Contact Info • Jackie Das – 480 213 0353 jackie.das@westpharma.com Tech Group Confidential

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