Transcript Slide 1
Seasonal Application of MSW/PSW Ralcorp Frozen Bakery Products Ogden, UT Introduction to the Business Seasonal Calendar Ogden, UT • Size of property = 9 acres • Main plant constructed in 1940’s (leased) • Produces packaged frozen cookies and waffles • 12 finished production lines • 2-3 frosted sugar cookie lines • 4 rotary cut cookie lines • 2 wire cut cookie lines (Meincke) • 1 no-bake cookie line • 1 assembly line • 2 waffle lines: •700+ SKUs •Theoretical capacity utilization Cookies = 62% (annualized) • Theoretical capacity utilization Griddle = 99% Ogden, UT – Basic Layout Ogden, UT Mixer Line 1 - Ogden Cell 1 Extruder Oven Cell 2 Unique Features: Tri-Ex Process Enrobing Products: Enrobe Cooling Tunnel Package/Palletize Cell 3 Ogden, UT Mixer Line 2 - Ogden Cell 1 Extruder Oven Cell 2 Unique Features: Enrobing Products: Enrobe Cooling Tunnel Package/Palletize Cell 3 Ogden, UT – Lines 1&2 Capacity Assumptions Without prebuild. Issues Opportunity Recommendation Prebuild Jun-Aug to smooth Sep-Nov Ogden, UT – Lines 1&2 Capacity Assumptions With prebuilds. Ramp up with everyday/harvest product production in June, Christmas in July Issues Opportunity Recommendation Costco Meinke bar cookie – 18000cs Ogden, UT Line 5 - Ogden Pre Scale FR. MIX Mixer Cell 1 Extruder Oven Cell 2 Unique Features: Auto Tray Packer Auto Palletizing Products: Frosting Cooling Tunnel Cell 3 Package/Palletize Cell 4 Ogden, UT Line 6 - Ogden Pre Scale FR. MIX Mixer Cell 1 Extruder Oven Cell 2 Unique Features: Wire-cut FSC’s Auto Palletizing Products: Frosting Cooling Tunnel Cell 3 Package/Palletize Cell 4 Ogden, UT Mixer Line 8 - Ogden Cell 1 Extruder Oven Cell 2 Unique Features: Wire-cut FSC’s Rotaries Trays Products: Frosting Cooling Tunnel Cell 3 Package/Palletize Cell 4 Ogden, UT – Lines 5,6,&8 Capacity Assumptions Issues Opportunity Recommendation Demand without Holiday pre-builds Ogden, UT – Lines 5,6,&8 Capacity Assumptions Issues Opportunity Recommendation Demand with Holiday pre-builds Prior Process Prior Process for MRP Prior Process • • • • • Excel-based, only using QAD as an input Macro / VB driven Many customized reports Maintained by one individual Burden to their system/network Prior Process – Seasonal Tracker Prior Process – Detailed Schedule Prior Process – Component Sched Prior Process – WO Reconciling Why transition? Why Transition? Why transition? • Excel process not supported • Cannot be upgraded easily • Corporate IT support near impossible • “Custom” to the plant and scheduler • Standard of work • • • • Community of users Training available Support within the company Maintain QAD – value added • More efficient • Workbench supported by IT, QAD • Regular patches and updates released • Less burden on the planners and systems Project Charter Planning Tool Decision • Outside Vendor • MSW/PSW (QAD) Project Timeline • Overview • Available to Promise Risks • Inputs • Solutions • Outputs MSW/PSW versus Outside Vendor Item MSW/PSW Outside Solution Software/Implementation Already in QAD $100K+ per site plus yearly fees Hardware cost Not needed Dedicated server needed per site Training QAD/Logan/Two other plants Provider-based Delivery time 3 months 6+ months Complexity Integrated within QAD Programming Logic – complex setup – must bridge with QAD Scheduling Create & Optimize within MSW/PSW. Manages schedule exceptions. Still requires up-front work orders. Schedule optimizer. Utilization Any plant as needed “One off” for Ogden – other plants lack the needed complexity Ogden MRP Timeline 2013 (weeks) 1/28 2/4 2/11 2/18 2/25 3/4 3/11 3/18 3/25 4/1 4/8 4/15 4/22 4/29 Charter Presentation/Signoff INPUTS • Forecasting • MRP Parameters • MSW Parameters/Setup APP TESTING & TRAINING • Available to Promise Test/Train Test/Train Live • Master Schedule Test Live • Detail Schedule Test Live Test Live Test Live • MSW/PSW OUTPUTS • Shop Floor Documents • Component Availability • CUTOVER / GO LIVE • SUPPORT Develop Parallel Live 5/6 Risks Inputs Forecast Inventory Planning Parameters Distribution Orders • Accuracy • Consumption Logic • Accuracy • “Dialing In” • New products • Timing Applications ATP Project MSW/PSW Workbook • Business agreement • Deliverable? • Minimal experience in frozen • No support • No off switch Outputs Component Availability Check • BOM Accuracy ATP Data Change Mgmt. KPI’s • Must account for freeze time (modification) • Plant buy in • Address concerns • Impact to CFR, DOH Custom Reports Custom Reports From this… To this. From this… To this. End result…