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QAD Enterprise Asset Management (EAM) MMUG Midwest Users Group March 16 - 18, 2008 John Woodburn Solution Consultant

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Presentation on theme: "QAD Enterprise Asset Management (EAM) MMUG Midwest Users Group March 16 - 18, 2008 John Woodburn Solution Consultant"— Presentation transcript:

1 QAD Enterprise Asset Management (EAM) MMUG Midwest Users Group March , 2008 John Woodburn Solution Consultant

2 QAD Proprietary Manufacturing Companys Challenges Companies are driven to find ways to: – Increase production output – Improve product quality – Reduce cost Plant Operations are responsible for a companys most critical assets, its production equipment. Reliable equipment will: – Maximize production performance – Minimize scrap / rework – Lower cost Costs 4X more to fix broken equipment than to maintain it

3 QAD Proprietary How QAD EAM Supports Manufacturing QAD EAM is responsible for the management of the manufacturing assets including; – The design, construction and commissioning – Operations and maintenance (preventive and repairs) – Replacement / upgrade of equipment Asset Lifecycle Management

4 QAD Proprietary The Solution QAD Enterprise Asset Management

5 QAD Proprietary QAD EAM for Plant Operations The QAD EAM suite provides three solutions: – Project Controls Management – Plant Maintenance – MRO Supply Chain MRO Inventory MRO Purchasing Plant Operations

6 QAD Proprietary Project Controls Management Types: Capital, Prototype, Expense, etc On-Time Delivery – Properly managed projects bring assets on line quicker Within Budget – A manager must have visibility and control of spending against a project Plant Operations

7 QAD Proprietary Plant Operations Plant Maintenance Goal: Maximize manufacturing equipment utilization and minimize repair costs Equipment breakdowns directly contributes to loss production, missed shipment dates and increased cost Comprehensive preventive maintenance program and increased positive control of corrective maintenance results in improved equipment reliability

8 QAD Proprietary Plant Operations MRO Inventory Support Production – By ensuring critical spare parts are on-hand when needed, production downtime can be minimized Lower MRO Inventory – A better understanding of critical spare parts requirements will lead to right sizing inventory, minimizing investment

9 QAD Proprietary Plant Operations MRO Purchasing Goal: Source critical spare parts from approved suppliers as quickly as possible at the lowest possible cost Improve Purchasing Efficiency & Control – Better purchasing control has helped companies reduce spending by sharing parts between sites and avoiding unnecessary purchases

10 QAD Proprietary Fully Integrated with QAD Enterprise Application 2007 QAD Enterprise Asset Management

11 QAD Proprietary Master Tables Cost Center Account / Sub-Account Projects Budgets Accounting Calendar Bill to Address Ship to Address Currency / Exchange Rates Suppliers Terms Standard Clauses ACCOUNTINGACCOUNTING PURCHASINGPURCHASING QAD FinancialsQAD EAM Master Tables Cost Center Account / Sub-Account Projects Budgets Accounting Calendar Bill to Address Ship to Address Currency / Exchange Rates Suppliers Terms Standard Clauses ACCOUNTINGACCOUNTING PURCHASINGPURCHASING Downloaded / Updated via Automatically

12 QAD Proprietary Purchase Requisition Purchase Order Purchase Order PO Receipt MRO Inventory Receipts Pending Voucher Unposted GL Expense QAD EAMQAD eB2.1 EAM POs can be received via EAM or QAD Unposted GL Purchasing Integration

13 QAD Proprietary Production Driven Maintenance (PDM) Scheduling Preventive Maintenance Based on Equipment Usage Table: opt_hist Work Center = L100 Machine = 60 Tool = T50 Part = F105 Qty = 5,000 Equipment Mapping MFGPRO EAM L = Press-A T50 = Die-10 UOM Conversion Part F105 = 2 cycles per 5,000 parts = 10,000 cycles Equipment (Press-A) Sub-component A Sub-component B Tool / Die (Die-10) EAM Equipment Structure QAD eB2.1 QAD EAM Create PM Work Orders

14 QAD Proprietary Getting Results QAD Enterprise Asset Management

15 QAD Proprietary Background Formed in 1995 as joint venture between Monsanto and Akzo Nobel. In 1997, Monsanto spun off its investment in Flexsys to Solutia Inc. Flexsys is a chemical manufacturing company. Its products help cure and protect the rubber, increase durability and fatigue life, control color and provide heat resistance. Manufacturing plants in US, Brazil, UK, Belgium, France, Germany, Italy, Malaysia and Japan

16 QAD Proprietary Why Focus on Maintenance Prior to 2003, Flexsys had been focusing on eliminating waste by adopting Oliver Wight Class A standards Although Flexsys achieved Class A certification, production performance remained below Class A levels – Production output in relation to plant capacity was around 75% – Class A levels required production output to be in excess of 90% One of the reasons was poor equipment reliability!

17 QAD Proprietary By the Numbers… Then and Now Production Scheduling Efficiency 83%95% Overall Equipment Effectiveness (OEE) 80%88% Maintenance related Down Time 10% - 15% <5% Reduction in Maintenance Budget12% Percentage of Reactionary Repairs 90%11%

18 QAD Proprietary Product Demo QAD Enterprise Asset Management


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