Implementing Shop Floor Reporting at Schrader Bridgeport

1. Implementing Shop Floor Reporting at Schrader Bridgeport Scott Kadak, Division Information Systems

2. About the Division • 300 employees • 3 shift operation • XA customer since 1983 • Currently XA release 6 • Utilize all Browser applications • Shop Floor Software: • MDCC – Manufacturing Data Collection & Communications • ATM – Advanced Transaction Management • PBLSi – Paper-Less Barcode Labeling for the iSeries Scott Kadak, Division Information Systems

3. About the Division • Schrader Bridgeport • Customers • Tier 1, 2 and 3 automotive suppliers • Automotive aftermarket • Industrial • Products • Tire valves • Fuel valves, air conditioning valves, valve cores • Pneumatic couplers and plugs • Various tire hardware equipment Scott Kadak, Division Information Systems

4. Why Implement Shop Floor Reporting • Re-Engineering the business to support standard, consistent, integrated business processes. • Shop floor activity is the heart of the operation • All material transactions were done manually • Transaction reporting was at best one day behind • Home grown stand alone labor reporting • Labor reporting transactions were done manually Scott Kadak, Division Information Systems

5. Why Implement Shop Floor Reporting • Shop floor data is fundamental for: • Inventory control • Scheduling • Material Planning • Costing • WIP was always a “black hole” Scott Kadak, Division Information Systems

6. What we expected to gain • Inventory accuracy • Labor time accuracy • Timely information • Free up material planners to do planning • Product identification • Use of discrete manufacturing orders Scott Kadak, Division Information Systems

7. Implementation Process • Started with high level educational overviews • Software features, functionality and setup options • Used a small work cell as a model / pilot • Spent time learning and working out process before expanding to other cells Scott Kadak, Division Information Systems

8. Implementation Process • Key factors: • Routing operations • Definition and setup of production facilities • Process: • Defined / created production facilities • Printed single level BOM with routing • Reviewed with shop floor supervisors and floor associates • Marked up to reflect actual process • Changed routings and BOM as needed Scott Kadak, Division Information Systems

9. Implementation Process • Training • Conducted 1 class room session with each associate • Explained process (TA, Job On, Job Off, …etc) • Provided handouts that matched screens exactly • Had each associate practice with touch screen • Go live • Provided hand holding • Stood by their side during reporting (TA, Job On, Job Off, …etc) Scott Kadak, Division Information Systems

10. Current Environment • Entire factory using Paper-Less for shop floor reporting • Hardware • 32 wireless kiosk stations consisting of: • Touch screen • HP thin client running Citrix • Zebra Stripe label printer Scott Kadak, Division Information Systems

11. Current Environment • Standard touch screen setup Scott Kadak, Division Information Systems

12. Paper-Less Processes • Time and Attendance Transactions • Job On Transactions • Individual Job On transactions • Crew Clocking transactions • Multiple associates working on the same job • Job Off Transactions • End of shift Job Off reporting • Multiple times within a shift reporting – Update Piece Count Scott Kadak, Division Information Systems

13. Paper-Less Processes • Material Issue Transactions (IP) • Individual material issue based upon physical picking process • Material issue based upon BOM operation were first used and routing operation reporting • Manufacturing Production Receipt (RM) • Stock location default via XA Production Facility master and Item Warehouse record default stock location Scott Kadak, Division Information Systems

14. Paper-Less Processes • Scrap Reporting • During Job Off (SM) • Scrap Component (SC) • Operation complete transaction • Manufacturing order complete transaction Scott Kadak, Division Information Systems

15. Paper-Less Enhancements • Standard features and functionality • Default stock location per production facility • Issue material from • Receive material into • Trigger program to refresh during order release • Hide EXIT and CANCEL buttons on Product Receipt Screen Scott Kadak, Division Information Systems

16. Paper-Less Enhancements • PBLSi – Paper-Less Barcode Labeling for the iSeries • Automated custom label printing triggered by XA and Paper-Less transactions. • Schrader Bridgeport Enhancements • Supervisor Report • Employee Production Report Scott Kadak, Division Information Systems

17. Paper-Less Enhancements • PBLSi – Paper-Less Barcode Labeling for the iSeries • When shop floor employee reports production against the first operation a 4 x 6 label is automatically produced. • When shop floor employee reports production against subsequent operations a ½ x 3 label is automatically produced. Scott Kadak, Division Information Systems

18. Paper-Less Enhancements Scott Kadak, Division Information Systems

19. Paper-Less Enhancements Scott Kadak, Division Information Systems

20. Paper-Less Enhancements Scott Kadak, Division Information Systems

21. Paper-Less Enhancements • Supervisor Report Scott Kadak, Division Information Systems

22. Keys To Success • Use the experts to assist with the implementation • Consultants • Supervisors, shop floor associates • Routings and Production Facilities are most important • Start with a small area • Supervisor training and education are critical • Training, persistence and patience are required with shop floor associates Scott Kadak, Division Information Systems