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QAD Manufacturing Product Strategy and Direction

QAD Manufacturing Product Strategy and Direction. Nicole Groves, Sr Staff Business Analyst, QAD Hank Canitz, Sr. Director Industry Marketing - QAD. Agenda. Manufacturing - Roll out plan 2010 Deliverables Process Manufacturing Beyond 2010 Our Vision. Manufacturing 2010 and Beyond.

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QAD Manufacturing Product Strategy and Direction

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  1. QAD Manufacturing Product Strategy and Direction Nicole Groves, Sr Staff Business Analyst, QAD Hank Canitz, Sr. Director Industry Marketing - QAD

  2. Agenda Manufacturing - Roll out plan • 2010 Deliverables • Process Manufacturing • Beyond 2010 • Our Vision

  3. Manufacturing 2010 and Beyond • Internationalization Support- Periodic Costing • Workbenches - MSW, PSW, Kanban Sizing • Inbound Logistics Accounting • Process Manufacturing • Integrated Mixed Mode Manufacturing • Subcontract Orders and Supply • Lean and Kanban Enhancements

  4. High Level Development Plan March 2010 Jun 2010 Sept 2011 Kanban Wkbch Production Orders Master Sched Wkbch (MSW) Subcontract Processing Production Sched Wkbch (PSW) Kanban Enhancements Logistic Accting Periodic Costing Process Phase 1 Process Phase 2 Process Phase 3.2 – 3.4 Process Phase 3.1 2010 2012 2011 4

  5. 2010 Deliverables

  6. 2010 Deliverables • 2010 EE – March, 2010 • Periodic Costing - Limited Availability • International Requirement • Compliance with legal tax requirements & IFRS • Actual cost evaluation methods: • WAVG • FIFO • LIFO General Availability – September 2010

  7. 2010 Deliverables • 2010 EE – March, 2010 • Periodic Costing - Limited Availability • International Requirement • Compliance with legal tax requirements & IFRS • Actual cost evaluation methods: • WAVG • FIFO • LIFO General Availability – September 2010 • Workbenches • Kanban Sizing Workbench • Kanban Process Workbench 2010 SE – June 2010

  8. Kanban & Process Sizing Workbenches

  9. 2010 Deliverables • 2010 SE – June, 2010 • Workbenches • Master Scheduling Workbench (MSW) • Production Scheduling Workbench (PSW) • Component Availability Check (CAC) Integration 2010.1 EE- September, 2010

  10. Planning & Scheduling – Future Flow Period - > Month - > Week - > Day - > Shift - > Interval - > hour Base PSW MSW MSW Base CAC Production Planned Production Dispatched Demand received Production Scheduled Production Reported • Production Dispatched (PSW) • Multi-Select • Auto Release • Export Dispatch List To Excel • (MSW) • Export Schedule To Excel • Production Dispatched (Base) • Integrated Component Availability Check • Integrated Single & Multi WO Print • View only security for shop floor personnel • Production Reported (Base) • Monitor WIP of production order • Monitor WIP of operations • Monitor WIP of production cum • Production Reported (PSW) • (MSW) • Monitor activity with visual completion indicators • Production Planned (MSW) • Capacity & Load Planning • Manage Scheduling Horizon • Apply Data Groupings/Filters • Select Views (daily-weekly-monthly) • Apply Totaling (KYB) • Apply Leveling (KYB) • Production Planned (Base) • Auto-Firm • Manage Production Order • Header Attributes • Operation Attributes • Date & Times Many new capabilities + 60> reports, inquiries, maintenance and process programs rolled up into the new Production Scheduler • Demand Received (MSW) • Exception Based Visual Indicators • Filtering by Exceptions • Control Content - Demand/Supply • Control Demand Sources • Demand Received (Base) • Integrated CRP calculates operation dates • Demand Detail Drilldown • Monitor Inventory

  11. MSW Overview Capacity Frame Displays capacity information per selected resource in the Schedule Grid - Balance your planned and required capacity. Schedule Grid The primary context of the workbench. - View and modify your production schedules for each item. Supply/Demand Frame Provides demand & supply information per selected item in the Schedule Grid. - Primary information used for scheduling decision making.

  12. Demand Details Tab Provides information related to item demand such as customer and order number information. MSW Overview Select Item in Schedule Grid

  13. Production Order Browse Locate un-sequenced production orders by attributes (red/yellow) (large/small). PSW Overview Drag & Drop the orders to the desired position on the Sequence Grid. Production Order Sequence Grid Schedule and sequence production orders by item attributes. Create a schedule by (release date, shift, sequence) Supporting Tabs

  14. PSW With CAC Integration Order Component Status Before releasing to shop floor, verify all component are available. Order Component (BOM) Frame Identify the components with shortages, scheduled receipts, partial issues. Select a component and drill down further into MRP and Inventory Details

  15. 2010 Planned Deliverables 2010.1 EE – September, 2010 Inbound Logistics Accounting Average Costing compatibility New manual option to enter logistics charge amounts when creating orders/shippers New calculation methods

  16. 2010 Planned Deliverables 2010.1 EE – September, 2010 Inbound Logistics Accounting Average Costing compatibility New manual option to enter logistics charge amounts when creating orders/shippers New calculation methods Process Industry Enhancements

  17. Process ManufacturingEnhancement Project Update Hank Canitz Sr. Director Industry Marketing - QAD Process ManufacturingEnhancement Project Update

  18. Process Manufacturing Industries Pharmaceutical & Biotechnology Processed Food & Beverages Chemical Products Industry Consumer Packaged Goods (Personal Care, Tobacco etc.) Other Industrials (Metal, Paper, Recycling,...) 18

  19. Main Characteristics Variable & Unstable Material Characteristics Formulas or recipes Complex Manufacturing Batch Manufacturing Highly Regulated Industry Quality Control & Quality Assurance Packaging, Labeling, Picking, Shipments, Transportation – “CPG” 19

  20. Process Manufacturing Advisory Board Continuing Efforts: Ongoing Conference calls Phase I Solution Testing Phase II Requirements Definition Accomplishments: Phase I Delivered for Early Adopters Team Prioritized Deliverables QAD Created Timeline • Currently 18 QAD customers are collaborating • 9 Pharmaceuticals & Biotech • 7 Food & Beverage • 2 Chemical Industry 20

  21. Process Manufacturers Advisory Board Main Goals Obtaining input from the customer-base Leveraging industry expertise and day-to-day knowledge Establishing process for defining and validating common requirements Improving quality and market acceptance of QAD’s future products & services Improve Time to Market through joint efforts Reducing customization & expanding QAD footprint Main Activities Understanding main pain points Documenting key business requirements Determining highest priority business requirements Establishing working groups for each development phase Testing and adopting new functionality

  22. Process Manufacturers Advisory Board Value Proposition for PMAB members Influence and help determine QAD’s future products & services for your industry Have direct access to product managers and QAD’s R&D Team Get new solutions up-front (Early Adopter Installation) Network with affiliated companies and learn from each other QAD’s expected engagement of PMAB members Share your valuable time and domain expertise Be on or plan to be on a recent release of QAD Enterprise Applications Commitment to implement new functionality and provide feedback Willingness to be a reference for new developed products

  23. Project Phases 23

  24. Development Plan May 2010 Nov 2010 March 2011 • 1.1 PHASE 1 • Formulas & Work Orders • Potency & Batch Balancing • 3.3 PHASE 3 • Complex Mfg • 2.3 PHASE 2 • Integration QMS • 1.2 PHASE 1 • Lot Traceability • Enhancements • 3.4 PHASE 3 • Formulas/Formulations • 3.2 PHASE 2 • Attributes (2) • 2.1 PHASE 2 • Attributes (1) • Quality • 2.2 PHASE 2 • Catch Weight/ • Dual UOM • 3.1 PHASE 3 • Packaging, Labels • Serialization QAD EE 2010.1 QAD EE 2011 QAD EE 2012 March 2010 September 2011 September 2009 September 2010 March 2011 March 2012 24

  25. 1.1 Phase 1 – Potency & Batch Balancing Aspirin (Acetylsalicylic acid) -A: Salicylic Acid -E: Sodium -E: Acetyl Chloride • Potency • Standard potency & tolerance ranges at item, item-site & supplier-Item Level • Lot potency for Inbound receipts, inventory & work orders • Batch Balancing • Automatic adjustments of WO BOM based on standard formulas and actual lot potencies of assigned materials following well-determined batch balancing rules • Option to re-balance batches manually any time after changes in allocated materials • Formula Management • Component categories to differentiate types of ingredients/components to be used • Standard formulas, with formula-specific standard potency & tolerance ranges • Alternate units of measure to define component quantities • Non-Scalable component capabilities • Work Orders • Printing of recipe documents • WO manual allocations 25

  26. 1.2 Phase 1 – Lot Track & Trace Enhancements • Lot Trace • Improved backward & forward lot traceability reporting • Lot management (lots / sub-lots) • Centralized lot attributes • Validations on lot attributes 26

  27. 2.1 Phase 2 – Quality & Attributes • Extended Attributes • Enabling additional item & lot attributes • Retest date, use by date, available from date, • Supplier lot, origin of goods,.. • Configurable / User-definable attributes • pH, moisture content, specific gravity, color, ... • Quality Enhancements • Supplier qualification • Enhancements regarding receipts & inspections • Additional validations during inventory transactions • Enhancements to inspections capabilities 27

  28. 2.2 Phase 2 – Dual UOM / Catch Weight • Unit of Measures • Alternate UOM & Rounding calculations • Inventory, formulas & work orders • Dual UOM / Catch Weight • Capture and track inventory in two units of measure • Value, order, price, ship, invoice, plan, allocate, produce, by catch-weight UOM & logistics UOM 28

  29. 2.3 Phase 2 – Integration QMS • Quality (2) • Integration with QMS (Cebos) 29

  30. 3.1 Phase 3 - Packaging/Serialization/Label Prints • Packaging, Labels, Serialization • Multiple Packaging Options & Packaging Sizes • Labels & required attributes • Serialized Packaging 30

  31. 3.2 Phase 3 – Extend functionality Attributes • Extended Attributes (2) • Lot Date Attributes & Business Logic in Planning & Order Promising • Lot Assay & Measurable Attributes – Additional Validations / Automatic Calculations • Carrying forward material-specific attributes to end-product • Flexible picking logics based on additional lot attributes • Addl shipping validations based on customer-based criteria 31

  32. 3.3 Phase 3 – Enhancements for Complex Mfg • Complex Manufacturing • Mixed-Mode / Hybrid-Mode Manufacturing • Co/By-Products • Multi-Stage Formula Defitions and WO Routings 32

  33. 3.4 Phase 3 – Formulas / Formulations Raw Materials Bulk Product Mixing/ Blending • Formulas/ Formulations • Recipe-based formulas using full .netUI capabilities • Rule-based formulas & work order processing • Formula configurations 33

  34. 1.1 Phase I - Screen Shots 34

  35. Master Data – Item Maintenance • Customer Item, Supplier Item Maintenance • Target Potency • Potency Tolerance • Potency Enforcement • Item, Item-Site Maintenance • Extended Attributes • Target Potency • Potency Tolerance • Potency Enforcement 35

  36. Master Data – Formula Maintenance • Specific Target Potency values • Potency Tolerance • Potency Enforcement • Component Type: Active, Excipient, Standard 36

  37. Lot Potency - Purchase Orders Receipts • PO Receipt • Target potency • Potency enforcement • Physical Quantity + Potency • Inventory • Lot Potency • Effective Quantity vs. Physical Quantity • Planning and Costing in Effective Quantities • Inventory movement in Physical Quantities 37

  38. WO Manual Allocations 38

  39. WO Detail Browse 39

  40. Development Plan May 2010 Nov 2010 March 2011 • 1.1 PHASE 1 • Formulas & Work Orders • Potency & Batch Balancing • 3.3 PHASE 3 • Complex Mfg • 2.3 PHASE 2 • Integration QMS • 1.2 PHASE 1 • Lot Traceability • Enhancements • 3.4 PHASE 3 • Formulas/Formulations • 3.2 PHASE 2 • Attributes (2) • 2.1 PHASE 2 • Attributes (1) • Quality • 2.2 PHASE 2 • Catch Weight/ • Dual UOM • 3.1 PHASE 3 • Packaging, Labels • Serialization QAD EE 2010.1 QAD EE 2011 QAD EE 2012 March 2010 September 2011 September 2009 September 2010 March 2011 March 2012 40

  41. Summary • Need more customer participation in PMAB • Looking for early adopters • Now: Phase 1.1 (Formulas, Potency & Batch Balancing) • June 2010: Phase 1.2 (Lot Traceability) • Jan 2011: Phase 2.1/3.1 (Catch-Weight and Packaging & Serialization) 41

  42. Beyond 2010

  43. Beyond 2010 MFG Product Themes • Modernization • Technologies (.Net, Reporting Framework) • Functional/Tool Expansion • Convergence/Reconciliation • Elimination of Duplication • Integration/Interoperability • Business Process Re-Engineering • Simplification • Usability • Redesign

  44. Beyond 2010 • Planning/Scheduling • Master Schedule Leveling • Gross Requirements Calculator

  45. Planning/Scheduling Process Flow Demand Mgmt S&OP OrderEntry 90% MPS Forecasts Production Plan Customer Orders Review / Adjust Master Schedule MSW/CAC Constrained Leveling (MPS Calc) Master Schedule Review / Adjust Production Schedule PSW/CAC MRP Subassemblies Purchased Items Authorized Production Procurement Manufacturing Execution

  46. Planning/Scheduling Process Flow - Kanban MRP/GRC HistoricalUsage Master Schedule Gross Requirements Average Demand, Safety StockCalc Average Demand Kanban Workbench(Sizing) Kanban SizingCalc Manufacturing Execution Kanban Cards

  47. Beyond 2010 • Manufacturing Execution • PSW • Production Orders ( Redesign of WOs and Repetitive Schedules) • Subcontract enhancements • Kanban enhancements

  48. Manufacturing Execution - Redesign • Production Orders • Discrete vs. Schedule • Material Management • Allocations, Picklists, Batch Balancing • Issue Policy, Issue, Transfer, Expense • Shop Floor Transactions • Common set for Discrete and Schedule • Sequencing

  49. Manufacturing Execution - Today

  50. Component Availability Check Manufacturing Execution – Beyond 2010 Planning Scheduling Report Labor Freeze BOM / Routing Scrap Batch Balancing Allocate Material Print Picklist Close Order Backflush Produce Subcontract Processing Transfer Material Issue Material Production Accounting Print Shop Papers Receive FG Release Order

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