a Unique Manufacturing Process Prashant Arya Director IT Agenda IAC Overview Carpet Manufacturing Model Process Mapping Outsourcing Model Lessons Learned 1 2 3 4 5 IAC ID: 427452
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Slide1
IAC
Customizing QAD for a Unique Manufacturing Process
Prashant
Arya |
Director IT Slide2Agenda
IAC
OverviewCarpet Manufacturing Model
Process
Mapping
Outsourcing Model
Lessons Learned
1
2
3
4
5Slide3IAC Global
Profile$4+ Billion Global Annual Sales
Leading Supplier of Automotive Components & Systems73 manufacturing facilities in 15 countries - 28,000 EmployeesProcess capabilities include CompressionInjection and Blow molding technologies
Various trimming and finishing methodsSlide4IAC’s Core Market Leadership Segments
Doors Panels
Armrests
Decorative appliqués
Map pockets
Switch bezels
Speaker grills
Safety components
Doors & Trim
Systems
Instrument Panels, Consoles & Cockpits
Flooring & Acoustic Systems
Headliner & Overhead Systems
Other Interior & Exterior Components
Instrument Panels
Cockpits
Center consoles
Hard & soft panels
Glove box assemblies
Air distribution products
Air registers
Decorative appliqués
Cup holder
Utility flooring
Floor Carpets
Floor mats
Acoustic insulators
Package trays
Trunk trim
Engine insulators
Wheel arch liners
Overhead systems
Headliner substratesGrab handlesOverhead consolesVisorsInterior lightingSafety systems
Interior
Cargo
Management
Load floors
Seat panels
Pillars
Exterior
Bumpers
Reservoir
Systems
Rocker
Panels
Exterior trimSlide5Customers are KeySlide6Business & IT ChallengesSlide7Carpet Process
(Rolled Goods) OverviewIAC manufactures two types of carpets
Woven Carpet – These are manufactured from YarnNon-Woven Carpet – Manufactured from Synthetic FiberCutting and slitting rolls with traceability to original parent rollManufacturing order allocation of assigned and unassigned rollsInventory availability by quality of roll across plants and warehouses Bill of material, recipe formula and dye lot
management Details of each carpet produced needs to maintain throughout the manufacturing process as well as post shipment for many yearsSlide8Carpet Process Workflow(Woven)
Preparing the Yarn
Yarn arrives at carpet manufacturer plant in form tubes or conesThese tubes or cones further wound to manufacture cones or Beam sets. These cones or Beam sets are transported to the Tufting machine
Tufting
In tufting process carpet is manufactured on specialized multi-needle sewing machines.
Yarn is fed from the creel , one tube of yarn for each needle , and threaded through the needles.
A tufting machine can produce several hundred square yards of carpet per day.
Dyeing
In Dyeing process tufted carpet rolls are sew-in together to make a continuous roll, which is then fed under rods that color the carpet.
There are other methods to dye the carpet.
Latex Coating / Shearing
In Latex Coating process, a coating of latex is applied to both the tufted, dyed carpets primary backing and secondary backing
Shearing is process of removing all of the little loose ends and projecting fibers that might have been created during the tufting process.
Inspection
Inspection is the final process where each carpet is carefully inspected for color uniformity and manufacturing defects before it is rolled, wrapped and shipped. Slide9Woven Carpet
Manufacturing Process
YarnCones or tubes of Yarn purchasedAssign Yarn to Creel
The Yarn Lot is assigned to Creel Location
Issue Yarn to Creel
Yarn is transferred to a creel location
Greige
Booking (Tufting
)
Production & Reporting of Tufted carpets
Inspection
Final production & reporting program were quality checks are done
Shipment
WO Creation
WO is created for each process after this like Dyed WO, Latex WO & Shearing WO
SEW-IN
The WO(Dyed, Latex or Shearing) are scanned to create the inspection records.Slide10Non-Woven
Carpet Manufacturing ProcessSlide11
IAC Carpet Process - ChallengesSlide12Key Solution Architecture Challenges
Capturing of Detailed Information relevant to Quality and Production at every stage
High Degree of Complexity & varied processes in Inspection & Production ReportingApproval Process for Lots & Dye RunsLack of Features in QAD to support Automobile Carpet ProcessSlide13Masters
– Process to QAD MappingSlide14Yarn –
Process to QAD MappingSlide15Greige Booking - Process to QAD MappingSlide16Inspection - Process to QAD MappingSlide17Quality - Process Mapping to QAD Slide18Implementation Approach
Business Analysis
Review Requirements / Mapping
U
nderstand system
requirements with the support from IAC Business
Team
Prepare
system requirements of current applications and “to-be
”
Submit the system requirements with high level mapping document.
Review findings and fine tune
.
Review system requirements / mapping with Business Team.
Finalize and obtain concurrence on the Solution Design / mapping.
2
Months - Plant
1
Month – India / US
Systems Development & launch
Develop extension as per approved technical specifications
Acceptance Testing
Deployment
Prepare launch plan along with IAC business and IT team
10 Months
Systems Analysis
& Design
Detailed Analysis, design, technical specification for Custom Developments, extensions and Reporting Solution.
Approval from IAC business and IT teams for development
4 Months
Systems Proposal
Vendor Submits
fixed bid proposal for analysis, design, development of System based on approved mapping.
IAC IT and business team reviews and approves the proposal.
Project kick-off
1 Month
Participation from IAC Team
Approval from IAC IT and Business Team
Acceptance Testing by IAC IT / Business Team
Design Approval by IAC IT / Business
Business / IT commitment for the project
OFFSHORE
ONSHORE MODELSlide19Development - Iterative Methodology
Iteration
Backlog
Iteration
3-8
weeks
On-Site Team
creates the Iteration Backlog
Test
& Fix
Defects
Up to
2
week
Continuous Integration
Requirements
Requirements
Requirements
Requirements
FS & TS creation/Approval
FS & TS creation/Approval
FS & TS creation/Approval
FS & TS creation/Approval
Code & Test
Code & Test
Code & Test
Code & Test
ITERATION CODE FREEZE
ITERATION ASSESSMENTSlide20Team StructureSlide21Lessons Learned