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Heil’s Integrated Platforming

Heil’s Integrated Platforming. Expected Heil Benefits Hard Savings 20% Productivity Gain 5% Direct Material Savings 25% - 40% Inventory Reduction Velocity Benefits 30% Lead-time Reduction 50% Reduction Time To Market Complexity Benefits 28 RCV Models to 6? 1 Control Architecture

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Heil’s Integrated Platforming

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  1. Heil’s Integrated Platforming • Expected Heil Benefits • Hard Savings • 20% Productivity Gain • 5% Direct Material Savings • 25% - 40% Inventory Reduction • Velocity Benefits • 30% Lead-time Reduction • 50% Reduction Time To Market • Complexity Benefits • 28 RCV Models to 6? • 1 Control Architecture • 40+% Reduction Part Numbers? • Reduced Fixed Costs From Scheduling Procurement Testing NPD Doc control Simplification • Warranty Reduction (?) + GUIDED SELLING TO PRECLUDE INCOMING UNFUNDED COMPLEXITY

  2. Original Objectives • Back in April/May 2012 the birth of Project GEM started with the following objectives in mind: • Phase 1: Technical PoC Validate SAP, JDE, Endeavor Commerce and PTC integrate with each other, while receiving best practices and direction to scope out Phase 2. • Phase 2: HalfPack 28 Yard PoC Create a limited, but complete process from Pro- E/Configurator through production with a confined option set for the 28 yard HalfPack. • Phase 3: Complete FEL Product family Create a limited, but complete process from Pro- E/Configurator through production with a confined option set for the 28 yard HalfPack.

  3. Leading Action Items(Conceptual - bypass ECO release process) • Engineering Bill of Material (BOM) Restructure: • Break down existing HalfPack 28YD Eject BOM structure into “modules” • Eliminate Drop/Add items (require both redesign and restructure) • Re-order/reshuffle components based on new restructure modules • Create new restructured modules in 3D/ProE • Re-order/reshuffle components based on new restructure modules • Define an absolute reference point for consistent module orientation and placement (and to set up for Skeleton model) • JD Edwards (JDE) BOM Restructure: • Create BOMs for new restructured modules • Eliminate Drop/Add items • Replace Phantoms with “Make” where ever applicable • Redefine Stocking Type, G/L Class, Line Type • Potentially eliminate NRM items • Configure a “Production-grade” Proof of Concept (PoC) Truck • Generate PoC Work Order • Eliminate Drop/Add • Redefine or eliminate Sales Part Numbers (SPNs)

  4. The Original PoC Quote • Non-CUSTOM dealer Commercial FEL Half Pack • 28 cubic yard body • Mack LEU chassis • Mack diesel engine with Allison transmission • Front mounted single pump • Optional 24” toolbox and 60 gallon washout tank

  5. The Break-down (PoC Picklist) • As result of joint effort among the Half Pack production line, at least 65 (and counting) standard modules were defined based on floor experience and potential variability of options within each module • Note there are more optional modules than standard modules • For more detail go to PoC Picklist spreadsheet PocPicklist

  6. BOM Structure Hierarchy - Today • Refer to 28YD HP Eject BOM spreadsheet

  7. BOM Structure Hierarchy - Tomorrow • Refer to 28YD HP Eject BOM spreadsheet • Advantages versus Today’s BOM Structure: • More flexible (add-on modular approach) • More accurate “real” cost • More streamlined work orders • More effective “real” time

  8. Configuration: Today vs GEM 14 vs 71 line items For example: 1 vs 32 in “Body” Source: JDE GEM.xlsx

  9. PoC 3D/ProE with Restructured Assembly Tree • Refer to video on exploded FEL Master

  10. Example of What to Restructure:Oil Tank Assembly 020-2474 • 5 levels deep under SPN • 49 line items • Eliminate Level 1 Phantom • Eliminate NRM • 3 new parts and 3 new BOMs (including converting 2 Phantoms) • GEM = 3 levels deep (cf to 6)

  11. Moving Target • During project GEM restructuring progress the following events have or will have been taken place: • Product rationalization nullified • CNG restructured into sub modules in various matrices • Electrical restructured into modules • Side Saddle (Streetwise) hydraulics to be implemented • New FEL matrices introduced • Next generation AFL to be “platformed” • New modeling and assembly standards to be introduced • Updated start parts with datum nomenclature and layering schemes • ModelCheck to drive model consistency • Skeleton models and Simplified Representations to be created at top level assemblies • Platforming Strategies workshop and meetings • Essentially a 28YD Half Pack configured today is structured quite differently compared to the original PoC quote in April/May 2012

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