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IAC Customizing QAD for IAC Customizing QAD for

IAC Customizing QAD for - PowerPoint Presentation

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IAC Customizing QAD for - PPT Presentation

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

process amp iac carpet amp process carpet iac business mapping yarn team requirements approval manufacturing systems qad tufting inspection

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Presentation Transcript

Slide1

IAC

Customizing QAD for a Unique Manufacturing Process

Prashant

Arya |

Director IT Slide2
Agenda

IAC

OverviewCarpet Manufacturing Model

Process

Mapping

Outsourcing Model

Lessons Learned

1

2

3

4

5Slide3
IAC 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 methodsSlide4
IAC’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 trimSlide5
Customers are KeySlide6
Business & IT ChallengesSlide7
Carpet 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 yearsSlide8
Carpet 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. Slide9
Woven 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.Slide10
Non-Woven

Carpet Manufacturing ProcessSlide11

IAC Carpet Process - ChallengesSlide12
Key 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 ProcessSlide13
Masters

– Process to QAD MappingSlide14
Yarn –

Process to QAD MappingSlide15
Greige Booking - Process to QAD MappingSlide16
Inspection - Process to QAD MappingSlide17
Quality - Process Mapping to QAD Slide18
Implementation 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 MODELSlide19
Development - 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 ASSESSMENTSlide20
Team StructureSlide21
Lessons Learned