February 2004. © Motorola All rights reserved.
NEMI Material Declaration PilotMotorola Results - EMARSTM
February 2004. © Motorola All rights reserved.
Agenda
1. Overview and Introductions2. Motorola Requirements and Selection Criteria3. Pilot Process Overview4. Part Compliance Evaluation5. Supplier Feedback6. Product Rollup & Reporting7. Response to Pilot Questions8. EMARS Features Review9. Pilot Results Summary
February 2004. © Motorola All rights reserved.
Overview and Introductions
February 2004. © Motorola All rights reserved.
Motorola Requirements and Selection Criteria
• Data Collection Tool– Automated data upload– Support 100% of supply base, including suppliers with minimal
IT Infrastructure– Perform basic validation of data against reporting requirements
i.e. mass balance, data structure, etc.
• Environmental Material Data Management andReporting– Link to existing Item Master
• Designer, Component Engineer and Supply Chain have access toall part data through a single tool
– Interface with multiple BoM Sources (ERP, PLM, flat file)– Scalable at the enterprise level– Proven database technology
February 2004. © Motorola All rights reserved.
Motorola Requirement and Selection Criteria, cont’d
– Support Full and Partial Disclosure i.e. part, materialand substance levels
– Handle multi-sourced components
– Generate reports at various BOM levels
– Support inputs from multiple sources such as IMDS,Excel based tools, RosettaNet, etc.
– Generate ad-hoc product reports
– Evaluate part compliance against multipleSpecifications
– Easy to use
February 2004. © Motorola All rights reserved.
High Level Motorola Architecture
ICCS System
• Item Master Management• Item & Industry Data Sheet Management• Item Numbering Management• Item Searching• Item Classification• Item Attribute Management• Supplier Management
ICCS System
• Item Master Management• Item & Industry Data Sheet Management• Item Numbering Management• Item Searching• Item Classification• Item Attribute Management• Supplier Management
PDM System
• Product Structure Management• Product Metadata and Content Data Management• Relationship Management• Version Control• Revision Control• Vaulting• Check-in and Check-out• Access Security• Configuration Management• Lifecycle Management• Workflow Management• Extranet Information Integration (Vendors/Suppliers )
PDM System
• Product Structure Management• Product Metadata and Content Data Management• Relationship Management• Version Control• Revision Control• Vaulting• Check-in and Check-out• Access Security• Configuration Management• Lifecycle Management• Workflow Management• Extranet Information Integration (Vendors/Suppliers )
Global Vendor Master System
• Purchasing• Accounts Payable
Global Vendor Master System
• Purchasing• Accounts Payable
New/Updated Vendors
New/SubscribedItems
BOMs , CAD/Mfg
Files
ECNs,Items , BOMs
BOMs , ECNs
ME SystemME System
New Items
Motorola Contract Information SystemMotorola Contract Information System
Workflow Requests
New/Subscribed Items
Quality Information Management System
• Supplier Quality Data• Global Supplier Part Qualification• Global Supplier Contact Database• Supplier Performance Recording
Quality Information Management System
• Supplier Quality Data• Global Supplier Part Qualification• Global Supplier Contact Database• Supplier Performance Recording
Supplier ItemRatings
Motorola Directory System
• User Profile Mgmt• Authentication
Motorola Directory System
• User Profile Mgmt• Authentication
New Items &Attribute Updates
DTM System
• NC Program Generation• Factory Data Management
DTM System
• NC Program Generation• Factory Data Management
ECNs, Specifications & Drawings
Conversion Cost System
• Product Cost Estimator• Product /Factory Modeler
Conversion Cost System
• Product Cost Estimator• Product /Factory Modeler
SMT Component Information
Library FilesLibrary Files
BOMs , Mfg Files
New/Updated Vendors
User Profile , Authorization
Link
Commodity Codes
Factory Setup Data
Simulation /Reuse Systems
• Design Library Management• Simulation• Re-Use
Design Engineering Systems
• ECAD• MCAD• CASE
EPM System
• Project Code Management
EPM System
• Project Code Management
Project Codes
NC ProgramNotifications
CAD Files
Portal
• Single Point of Entry• Application Dashboard
Portal
• Single Point of Entry• Application Dashboard
Link
Link
Global Chart of Accounts System
• APC Management
Global Chart of Accounts System
• APC Management
LC System
• Program Execution
LC System
• Program Execution
NC Programs
APC
APC
Parametric Data
ERP Systems
• Inventory• BOM• Engineering• EPO Structured
Items
ERP Systems
• Inventory• BOM• Engineering• EPO Structured
Items
EMARS integratesinto all necessary
systems
February 2004. © Motorola All rights reserved.
Pilot Process Overview
• Data Collection– Motorola invited 6 suppliers to participate in the pilot– Each supplier completed a spreadsheet and the evaluation
questionnaire
• Supplier Part Management– Data verified, validated and uploaded via EMARS– Compliance of parts assessed against specified thresholds and
application exemptions per Motorola’s W18 ControlledSubstance list (equivalent to Annex A of JIG)
• Product Reporting– Sample BOM reports created show the results for:
• Material content aggregated at top level• Worst case analysis for multi-sourced components• Parts missing information• Status of each part against Motorola’s spec
February 2004. © Motorola All rights reserved.
Part Compliance - Data Collection Flow
Supplier
Complete spreadsheet andsend to designated
Mot email Account
Reviewer
EmailAccount
Distribute to Reviewer
Further validation,
Create and run dbload
User
Manage, aggregate andreport data solution
Upload Utility
Enter data to IMDS
IMDS
EMARS-IMDS interface
February 2004. © Motorola All rights reserved.
Part Compliance - Process Flow
Request to Supplier
Baseline & ArchiveMonitorExemptions
Multiple Sourcing Engine
Item Master
Compliance
ConnectT M RosettaNetXML IMDS
ManualInput
W18 QuestionnaireManageExemptions
Compliance CheckerROHS/WEEEJIGELV/VDA
TM
February 2004. © Motorola All rights reserved.
Part Compliance Evaluation
February 2004. © Motorola All rights reserved.
Part Compliance Evaluation
February 2004. © Motorola All rights reserved.
Part Compliance - Status Report
February 2004. © Motorola All rights reserved.
Compliance Specification Report
February 2004. © Motorola All rights reserved.
Supplier Feedback - Profiles
• Supplier B – US based connector manufacturer, 2003revenues in excess of US $2 billion
• Supplier D – Japanese based passive manufacturer,2003 revenues of approximately US $10 billion
• Supplied F – US based capacitor manufacturer withrevenues in excess of US $400 million
• Supplier H – US based semiconductor manufacturer,2003 revenue approx. US $2 billion
• Supplier X – US based mechanical componentmanufacturer
• Supplier Z – Taiwanese based privately held PCBmanufacturer
February 2004. © Motorola All rights reserved.
Supplier Feedback – Reponses Summary
Compliance Connect – Supplier D• How many times have you used this tool? Approx.
16-18 times (submissions)• How easy or difficult was the tool to use? Initially
there were complications, but we’ve managed tocorrect the team.
• What barriers do you see in adopting the toolacross your company? Communicatingresponsibility between the various EngineeringGroups to complete the data.
February 2004. © Motorola All rights reserved.
Supplier Feedback – Reponses Summary
Supplier F - Compliance Connect and IMDS• How many times have you used this tool? IMDS used for 2 – 3 years,
Compliance Connect for over 1 year. We have used IMDS more often.We have approximately 3,000 entries in IMDS and several hundred inCompliance Connect.
• What was the total time to fill out the information into the tool (e.g.from the time you received the request until you were ready to send)?Per part type 30 – 45 minutes if a template to copy from does not alreadyexsits. With a template that can be copied from, time required drops tounder 12 minutes.
• What was your experience during the data entry process (positivesand negatives)? IMDS has slow response times during certain times ofday. Speed is slow in general. System shuts down regularly. Noprompting that text messages are there. No mass update options forchanges made to a part family – cannot group by anything. Complianceconnect is superior in all these areas.
• What suggestions and improvements do you recommend? DropIMDS and move to Compliance Connect.
February 2004. © Motorola All rights reserved.
Supplier Feedback – Reponses Summary
Supplier H – Compliance Connect
• How many times have you used this tool? Hundreds
• How easy or difficult was the tool to use? Easy
• How would you describe the help features and clarity of instructions?OK. I probably referred to them initially, but I do not remember usingthem.
• What was your experience during the installation (if applicable,positives and negatives)? I had problems running it on our system atfirst, had to run it on desktop. But I think that was an internal systemproblem and not a Compliance Connect problem.
• What was your experience during the data entry process (positivesand negatives)? I have used the system so much I have no problemswith it. One issue I do have is upgrades. I have all the parts andmaterials loaded in an older version. I have been asked to use a newerversion, which I have not done and will not do until it is absolutelyrequired, because I do not want to recreate all the materials in the newsoftware. Perhaps it can be copied onto the new version, but I tried thatand failed. I do not have the spare time to mess with it so I did notcontinue.
February 2004. © Motorola All rights reserved.
Supplier H – Compliance Connect, cont’d• What was the total time to fill out the information into the tool (e.g.
from the time you received the request until you where ready to send)?I did not do it, because It would have been a waste of my time. It probablywould have taken 15 – 30 minutes to input the data, create materials, etc.
• What suggestions and improvements do you recommend? Ifcompanies want their suppliers to use this software they need to keep itstable. It is very time consuming using it when you consider all the parts forwhich data has to be entered every month, year, etc. To have to updatepreviously input data is asking too much. To minimize the cost impact onsuppliers, software like this should be developed for use by admin levelpeople and should not require a college degree, eg engineering. I do notbelieve that is the case now.
• What barriers do you see in adopting the tool across your company? Ido not know what you mean by “adopting the tool across your company.”But if you mean having many people in our company supplying data tocustomers using Compliance Connect, it is too time consuming andtherefore expensive. It has to be used by one or a few people, whomaintain a high level of competence with it. Now I am the only person whouses it in my company, and I cannot find anyone to unload it onto. It is anaccident of history that I am doing this.
Supplier Feedback – Reponses Summary
February 2004. © Motorola All rights reserved.
Supplier Feedback – Reponses Summary
Supplier X - Compliance Connect
• How many times have you used this tool? Three times,once each for Motorola Northbrook Il , Schaumberg Il andWorld Wide Strategic Sourcing and Supply Management,Personal Communications Sector
• How easy or difficult was the tool to use? It was fairlyeasy even for an untrained person such as myself. Eachtime easier as I became more familiar with the document.
• What was your experience during the installation (ifapplicable, positives and negatives)? I essentially filledout paper copies only as this is what I was given by othersin our organization.
• What was your experience during the data entryprocess (positives and negatives)? I feel that due to thefact we only supply aluminum alloy parts that theinformation is repeated un-necessarily
February 2004. © Motorola All rights reserved.
Supplier Feedback – Reponses SummarySupplier Z - Compliance Connect• How many times have you used this tool? 3 Times.• How easy or difficult was the tool to use? The instructions are
easy to follow and thorough. However, entering the data is verylabor intensive and because of the macros used in the program,data cannot be copied into the spreadsheet from anotherdatabase or spreadsheet source.
• What was the total time to fill out the information into the tool(e.g. from the time you received the request until you whereready to send)? 8 hours.
• What suggestions and improvements do you recommend?Provide list of requested parts at time of request to supplier. Also,the large number of macros on the program make it clear what theinstructions are but they make it difficult to import data fromanother source. We realize this is because one generic form isused for all commodities, but it is quite tedious and labor intensiveto enter the data.
• What was your experience during the reporting / dataexchange (positives and negatives)? Easy output to CXS file.Submission is electronic so this is easy.
February 2004. © Motorola All rights reserved.
Product Aggregation and Reporting - Process FlowDynamically View Bill of Materials
ERP PLM Excel Flat File
Data Exchange Protocols•Compliance Connect•RosettaNet•IMDS•Custom Format
Full Disclosure Enabled Reporting
Material Aggregation & Worst Case Analysis
Multiple Sourcing Engine
Complete or Selective Aggregation
Search by Customer or Internal Number
February 2004. © Motorola All rights reserved.
Product Aggregation and Reporting -Overview• Populated pilot BOM to ERP (not stored in
EMARS)
• Generated reports to:– identify the reporting and compliance status of
all BOM items
– review component by component materialcontent, and
– review product material content aggregated attop level
• Worst case analysis for multi-sourced parts
February 2004. © Motorola All rights reserved.
Reporting and Compliance Status Report
February 2004. © Motorola All rights reserved.
Reporting and Compliance Status Report
February 2004. © Motorola All rights reserved.
Product Reports
• Refer to Excel Component by Componentreport
• Refer to Excel Top Level AggregatedProduct Report
February 2004. © Motorola All rights reserved.
Product Report
EMARS allows Selective or Complete Aggregation
February 2004. © Motorola All rights reserved.
Product Report
and supports multiple sourcing of parts
Worst Case AnalysisWorst Case AnalysisSupplier A Supplier B
February 2004. © Motorola All rights reserved.
Component Material Content Report
February 2004. © Motorola All rights reserved.
Response to Pilot Questions - Motorola
• How many times have you used the tool?– EMARS is in production for the Motorola Automotive products
group. Currently used for reporting of 7000 parts frommanufacturers and 250 products to customers.
– Corporate-wide deployment is underway• Data exchange process, tools and data fields?
– Suppliers provided information using the IMDS Interface (XML)and the Compliance Connect™ spreadsheet.
• Compliance with JIG Annex A?– The compliance validations were evaluated against the internal
Motorola specification which has the same controlled substancelist as JIG Annex A.
• Compliance with internal requirements? Customerrequirements? Current regulations?– EMARS was designed to comply with Motorola’s internal
requirements and with all its current customer and regulatoryrequirements in both the automotive and electronics industries.
February 2004. © Motorola All rights reserved.
Response to Pilot Questions, cont’d
• How accurate are the results? How was dataintegrity ensured?– The tool contains validation checks at all data transfer
stages.• The collection tools have checks to validate the integrity of
the data format and that reporting requirements are met bysuppliers.
• Data is then reviewed and processed by a technical expertprior to upload.
• The upload utility further verifies that the data complies withthe necessary parameters for it to load into Motorola’ssystem.
– In addition, product aggregation reports and worst-case analysis calculations were validated byscientists at Motorola Labs.
– Worst case analysis reports also present tolerancepercentages for each value.
February 2004. © Motorola All rights reserved.
Response to Pilot Questions, cont’d
• Cost, effort, and time to run the pilot?– Pilot was completed over a two week period of time
with minimal cost and effort, as the system is alreadyinstalled and running at our company.
– The implementation of EMARS allowed for a 90%reduction in the time and effort invested to completeand submit a material content report.
• Ease of use?– Web based user interface that requires no client
installation.– Part Qualification engine walks user through all
criteria for the evaluation of
February 2004. © Motorola All rights reserved.
EMARS Part FunctionalitySupplier Part Functionality EMARS CommentsSearch by
Supplier or Motorola Part Number r
Compliance Status r
Supplier (Name or ID) r
Date Material Declaration Received r
Controlled Substance r
Part Compliance
View Material Breakdown r
Calculate/view Compliance Status for Multiple Standards r
View Compliance Report r
Support for Compliance Exemptions r
NotificationsNotify when new part data is added r
Notify prior to exemption expiration r Not Appliable to Pilot
February 2004. © Motorola All rights reserved.
EMARS Product Functionality
Product Reporting Functionality EMARS CommentsSearch by
Motorola or Customer Part Number r
Customer r
Product Information
Retrive BOM Data from existing Systems r Single system used for pilot.
View Product Reporting History r N/A for pilot
View Single Level BOM Rollup r
View Multi Level BOM Rollup r
View Compliance Status for each item on the BOM r
Product Aggregation
Complete or Selective Aggregation r
Worst case analysis for multi-sourced items r
Report per multiple standards/data formats r
February 2004. © Motorola All rights reserved.
Summary of Pilot Results
• Pilot test process completed successfully andwith no issues
• Parts compliance status assessed againstMotorola/JIG standards
• Reports generate both at component andproduct level
• All major reporting features are available inEMARS tool to support Motorola’s businessneeds
• EMARS integrates with existing engineering andmanufacturing infrastructure. No need for datamigration or recurring updates of anotherdatabase.