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A Partner Connect Webinar

Integrated Best-in-Breed Project Manufacturing SolutionsPaul Whiteman

October 1, 2019

A Partner Connect Webinar

Paul WhitemanPartner

Lexell Blue, LLC

Speaker

Lexell Blue Services

» Costpoint/TESS Implementations and Re-Implementations

» Costpoint Materials/Manufacturing

» Data Migration, Restructures, M&A Integration and Divestitures

» Cognos Report development

» Product Installations, Upgrades & O&M

» Costpoint Health Check/Product Usage Assessments

» Project Management

Agenda» Introduction

» ‘Best in Breed’ manufacturing systems

» Manufacturing maturity and integration

» ERP – PLM

» ERP – MES

» ERP – QMS

» ERP – Shop Floor Labor

» ERP – APS

» Implementing integrated systems

» Summary

How to control the chaos?

Project Manufacturing Life Cycle Business Processes

‘Best in Breed’ Systems

Product Lifecycle Management

Manufacturing Execution (MES)

Quality Management

System (QMS)

Capacity Planning & Scheduling

Shop Floor Labor

Materials Requirements

Planning (MRP)

Enterprise Resource

Management (ERP)

‘Best in Breed’ Concepts» Leverage rich capability of purpose built tools within your industry, business model and

product set

» Aerospace & Defense Federal Contracting

» Engineer/Build to Order

» Build to Print

» Complex/Discrete Manufacturing

» Leverage the knowledge base of vendors and consultants focused on your industry to provide Industry Best Practices

» Leverage Integration and Automation technologies to connect systems

Compliance

» DFARS Business Systems

» Accounting

» Materials Management Accounting System (MMAS)

» Purchasing (CPSR)

» Property

DFAR 252.242-7004 Material Management Accounting System.As prescribed in 242.7204, use the following clause:MATERIAL MANAGEMENT AND ACCOUNTING SYSTEM (JUL 2009)(b) General. The Contractor shall—(1) Maintain an MMAS that—(i) Reasonably forecasts mate

ii) Ensure(iii) Maintains a

(2) Assess its MMAS and take reasonable action to comply with the .(c) Disclosure and maintenance requirements. The Contractor shall—

(1) Have policies, procedures, and operating instructions that adequately

(2) Provide to the Administrative Contracting Officer (ACO), upon request, t

(3) Disclose significant changes in its MMAS to the ACO at least 30 days prior to(d) Deficiencies.(1) If the Contractor receives a report from the ACO that identifies any deficiencies in :

Compliance

» Product Traceability

» Quality

» CDRL – Contract Data Requirements List

DFAR 252.242-7004 Material Management Accounting System.As prescribed in 242.7204, use the following clause:MATERIAL MANAGEMENT AND ACCOUNTING SYSTEM (JUL 2009)(b) General. The Contractor shall—(1) Maintain an MMAS that—(i) Reasonably forecasts mate

ii) Ensure(iii) Maintains a

(2) Assess its MMAS and take reasonable action to comply with the .(c) Disclosure and maintenance requirements. The Contractor shall—

(1) Have policies, procedures, and operating instructions that adequately

(2) Provide to the Administrative Contracting Officer (ACO), upon request, t

(3) Disclose significant changes in its MMAS to the ACO at least 30 days prior to(d) Deficiencies.(1) If the Contractor receives a report from the ACO that identifies any deficiencies in :

Manufacturing Maturity

11Solution Sophistication

Procurement

Product Definition

InventoryManagement

Bills of Materials

Production WIP Control

Sales Orders

Routings

BarcodingECN

APSCapacity Planning

Shop Floor Labor

Integration & Automation

Impacts to Manufacturing Maturity

» Product lifecycle stages

» R&D Research & Development

» LRIP Low Rate Initial Production

» FRP Full Rate Production

» Business size

» Management / Leadership

» Staff / Resource turnover

ERP - MRP

Materials Requirements

Planning (MRP)

Project Financials (ERP)

» Your Supply Chain and MRP needs to be tightly connected to your financial/billing system – compliance risks

» MRP systems integrated to Financial Systems is not typical or recommended

» Difficulties tracing costs from source through to financial reporting and billing

» Choose a system that will provide project financial compliance and project based MRP

PO’sReceiptsJournal Entries

ERP / MRP - Project Financials- Procurement- Inventory- Production Control- MRP

ProjectsSuppliers

Bills of Material Management

Key questions that need to be answered:

» What system owns the Part maintenance?

» What system owns the MBOM? PLM, ERP or MES

» How will you compare BOMs?

» What system will record the As-Built Configuration?

As-Proposed As-Designed As-Planned As-Built As-Maintained

PBOMProposal

Bill of Material

EBOMEngineering

Bill of Material

MBOMManufacturing Bill of Material

As-BuiltBill of Material

As-Maintained

Bill of Material

ERP – PLM/PDM

ERP / MRP

PLM / PDM

VendorsManufacturersCommodity Codes

PartsEBOM or MBOM

Engineering ChangesBOM Revisions

» Product Lifecycle Management (PLM) provides:

» Managing product changes through design, development through to obsolescence

» BOM Configuration Management

» Product Data Management (PDM)

ERP – PLM/PDM

ERP / MRP

PLM / PDM

VendorsManufacturersCommodity Codes

PartsEBOM or MBOM

Engineering ChangesBOM Revisions

» Historically data transferred was limited to Parts and BOMs, with ECN’s manually replicated

» Integrating ECN’s from initiation through to implementation provides supply chain impacts

ERP – MES

ERP / MRP

Basic RoutingsWork Order UpdatesWork Order Completions

PartsCharge Number

MBOMWork Centers

OperationsWork Orders

Warehouse LocationsWork Order Issues

» Manufacturing Execution System (MES) provides:» Process Planning and Execution» Paperless Work Instructions» Data Collections» As-Built Configuration

» Most ERP/MRP systems are ‘light’ on MES» The shop floor finally goes ‘paperless’

ERP – QMS

ERP / MRP

QC InspectionsVendor Status

PartsCharge Number

VendorsPO / ReceiptsWork Orders

» Quality Management System (QMS) provides:» Non-conformance tracking» Inspection planning and execution» CAPA» Quality metrics/reporting» Tool/Gauge management» Vendor performance

» Most ERP/MRP systems are ‘light’ on Quality capability

ERP – QMS - MES

ERP / MRP

» If separate QMS and MES tools used, requires more integration points

» Alternative is to leverage tools that provide both MES and QMS capability

Non-Conformance

MES/QMS

ERP / MRP

ERP – Shop Floor Labor

» Shop Floor Labor provides:

» Real-Time Work Order start/stop times

» Support complex shop floor pay rules and schedules

» DCAA time capture compliance

» Accurate Time and Attendance tracking

» Priority only if real-time labor a requirement

Shop Floor Labor

ERP / MRP

TimesheetsOperation Completions

EmployeesWork Centers

Charge NumbersWork Order /

Operations

ERP – Shop Floor Labor - MES

» If using an MES, integrate with Shop Floor Labor to leverage operator/technician operation start/stop

Shop Floor Labor

ERP / MRP

TimesheetsTimesheet Approvals

EmployeesWork Centers

Charge Numbers

Work Order / Operations

Operator Sign on/off

ERP – APS

APS Capacity Planning & Scheduling

ERP / MRP

Work Order Schedule Updates

Work CentersWork OrdersMRP Rqmts

» Advanced Planning & Scheduling (APS) provides:» Finite capacity planning, Work Order scheduling» Identify bottlenecks» What-If scenario planning» Near/long term resource planning

» Most MRP systems are infinite capacity planning tools» Typically mature manufacturing operations integrated

ERP/MRP to APS solutions» Dependent on accurate Resource Capacity and

Operation Setup/Run times

Benefits of integrating solutions

» Removing ‘swivel-chair’ activity

» Improves resource efficiencies

» Improves data accuracy

» Improves data timeliness

Implementing Integrated Solutions

» Best practices and tips

» Integrate when business processes and tools are mature (not always feasible)

» Develop an integration roadmap and work towards the fully integrated goal

» Secure handling of sensitive data (ITAR/EAR) in integrations

» Include error handling processes and auditing capability

» Real-Time (or near Real-Time) interfaces keep systems in sync

» Best practices and tips

» Ensure all systems using common Part and Revision identification

» Define only one system of record for each data object, and lock down the other systems if possible

» Leverage Vendor provided integrations/connectors where possible

» Technologies» ETL tools» Flat file imports» Web Services / XML» Database scripts (not recommended)

» File transfer frequency» Scheduled batch files » Real-Time (or near Real-Time)

Deltek’s Project Manufacturing Solution

Costpoint MES

Costpoint Shop Floor

Employee Clockings (Start / Stop)Work Order / Operation Releases

Costpoint

Employee review and sign time cardEmployee Self Service

Labor and time clockings

Employees, MO’s, Accounts, Project, Organizations, Work Centers/Operations, Project Workforce, Inv Abbrev, Parts, MBOM etc.

Routings, Labor reports and completions

Time and Attendance, Approvals, Completions

Touch Points: Costpoint and MES

DeltekCostpoint 7.1.1

Deltek CPMES

Employee DataParts

Manufacturing BOMsProject/Acct/Org

Account/OrgWarehouses/Locations

Work CentersOperations

Manufacturing OrdersMO Inventory Issues

Routings/Operationalized BOMsMO Routing Updates

MO Requirement UpdatesManufacturing Order CompletionsManufacturing Order Inspections

Touch Points: Costpoint and Shop Floor Time

DeltekCostpoint 7.1.1

Deltek Shop Floor Time

Employee DataEmployee Leave Data

Project/Acct/OrgAccount/Org

PLCProject Workforce

Work CentersManufacturing Orders

Routings

Manufacturing Order CompletionsManufacturing Order Inspections

Time Sheet LinesTime Sheet Approvals

Summary

» Compliance is King - leverage ‘Best in Breed’ tools within industry

» Plan out your integrated solution roadmap, and adopt as business processes mature

» Leverage Vendor provided integrations where possible

Questions?

Paul Whiteman

Partner – Lexell Blue

Ph: 571-214-9613

paulwhiteman@lexellblue.com

www.lexellblue.com

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