NEMI Material Declaration Pilot Motorola Results

Transcription

NEMI Material Declaration Pilot
TM
Motorola Results - EMARS
February 2004. © Motorola All rights reserved.
Agenda
1.
2.
3.
4.
5.
6.
7.
8.
9.
Overview and Introductions
Motorola Requirements and Selection Criteria
Pilot Process Overview
Part Compliance Evaluation
Supplier Feedback
Product Rollup & Reporting
Response to Pilot Questions
EMARS Features Review
Pilot Results Summary
Overview and Introductions
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 and
Reporting
– Link to existing Item Master
• Designer, Component Engineer and Supply Chain have access to
all part data through a single tool
– Interface with multiple BoM Sources (ERP, PLM, flat file)
– Scalable at the enterprise level
– Proven database technology
Motorola Requirement and Selection Criteria, cont’d
– Support Full and Partial Disclosure i.e. part, material
and 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 multiple
Specifications
– Easy to use
High Level Motorola Architecture
EPM System
EPM System
•
Project Code Management
•
Project Code Management
Global Chart of Accounts System
Global Chart of Accounts System
•
APC Management
•
APC Management
Global Vendor Master System
Global Vendor Master System
•
Purchasing
• • Accounts
Purchasing
Payable
•
Accounts Payable
Motorola Contract Information System
Motorola Contract Information System
APC
N e w/Updated
Vendors
User Profile ,
Authorization
Commodity Codes
New Items
Project Codes
N e w/Updated Vendors
ICCS System
ICCS System
•
Item Master Management
• • Item
Item
& Industry
Master Management
Data Sheet Management
•
Item
& Industry
Data Sheet Management
•
Item
Numbering
Management
• • Item
Item
Searching
Numbering Management
Item
Searching
• • Item
Classification
• • Item
Item
Attribute
Classification
Management
Item Attribute
Management
• • Supplier
Management
•
Supplier Management
Parametric Data
Supplier Item
New Items &
Ratings
Attribute Updates
Quality Information Management System
Quality Information Management System
•
Supplier Quality Data
Supplier
Quality
• • Global
Supplier
PartData
Qualification
• • Global
Global
Supplier
Supplier
Contact
Part Qualification
Database
Global Performance
Supplier Contact
Database
• • Supplier
Recording
•
Supplier Performance Recording
APC
Portal
Portal
•
Single Point of Entry
• • Application
Single Point
Dashboard
of Entry
•
Application Dashboard
Link
PDM System
PDM System
•
Product Structure Management
Product
Structure
Management
• • Product
Metadata
and
Content Data Management
• • Relationship
Product Metadata
Management
and Content Data Management
•
Relationship
Management
•
Version Control
• • Revision
VersionControl
Control
Revision Control
• • Vaulting
• • C hVaulting
e c k-in and Check-out
C h e c Security
k-in and Check-out
• • Access
• • Configuration
Access Security
Management
Configuration
Management
• • Lifecycle
Management
• • Workflow
Lifecycle
Management
Management
Workflow
Management
• • Extranet
Information
Integration
(Vendors/Suppliers )
•
Extranet Information Integration
(Vendors/Suppliers )
EMARS integrates
into all necessary
systems
N e w/ Subscribed Items
N e w/Subscribed
Items
ECNs, Specifications &
Drawings
ERP Systems
ERP Systems
•
Inventory
Inventory
• • BOM
• • Engineering
BOM
•
Engineering
•
EPO
Structured
• Items
EPO Structured
Items
LC System
LC System
•
Program Execution
•
Program Execution
Link
Workflow Requests
Factory Setup Data
NC
Programs
ECNs,
Items ,
BOMs
Library Files
Simulation /Reuse Systems
•
•
•
Link
DTM System
DTM System
•
NC Program Generation
• • Factory
NC Program
Data Management
Generation
•
Factory Data Management
NC Program
Notifications
BOMs , ECNs
SMT Component Information
BOMs ,
CAD/ Mfg
Files
Library Files
BOMs ,
Mfg Files
CAD Files
Design Library Management
Simulation
R e-U s e
Design Engineering Systems
•
•
•
ME System
ME System
Conversion Cost System
Conversion Cost System
•
Product Cost Estimator
Product
Cost Estimator
• • Product
/Factory
Modeler
•
Product /Factory Modeler
Motorola Directory System
Motorola Directory System
•
User Profile Mgmt
User Profile Mgmt
• • Authentication
•
Authentication
ECAD
MCAD
CASE
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 Controlled
Substance 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
Part Compliance - Data Collection Flow
Complete spreadsheet and
send to designated
Mot email Account
Distribute to Reviewer
Further validation,
Create and run dbload
Reviewer
Supplier
Email
Account
Upload Utility
User
Manage, aggregate and
report data solution
Enter data to IMDS
EMARS-IMDS interface
IMDS
Part Compliance - Process Flow
Request to Supplier
Compliance
ConnectT M
RosettaNet
XML
IMDS
Manual
Input
Item Master
ROHS/WEEE
JIG
ELV/VDA
Multiple Sourcing Engine
Compliance Checker
Manage
Exemptions
W18 Questionnaire
Monitor
Exemptions
Baseline & Archive
TM
Part Compliance - Status Report
Compliance Specification Report
Supplier Feedback - Profiles
• Supplier B – US based connector manufacturer, 2003
revenues 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 with
revenues in excess of US $400 million
• Supplier H – US based semiconductor manufacturer,
2003 revenue approx. US $2 billion
• Supplier X – US based mechanical component
manufacturer
• Supplier Z – Taiwanese based privately held PCB
manufacturer
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 to
correct the team.
•
What barriers do you see in adopting the tool
across your company? Communicating
responsibility between the various Engineering
Groups to complete the data.
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 in
Compliance 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 already
exsits. With a template that can be copied from, time required drops to
under 12 minutes.
•
What was your experience during the data entry process (positives
and negatives)? IMDS has slow response times during certain times of
day. Speed is slow in general. System shuts down regularly. No
prompting that text messages are there. No mass update options for
changes made to a part family – cannot group by anything. Compliance
connect is superior in all these areas.
•
What suggestions and improvements do you recommend? Drop
IMDS and move to Compliance Connect.
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 using
them.
•
What was your experience during the installation (if applicable,
positives and negatives)? I had problems running it on our system at
first, had to run it on desktop. But I think that was an internal system
problem and not a Compliance Connect problem.
•
What was your experience during the data entry process (positives
and negatives)? I have used the system so much I have no problems
with it. One issue I do have is upgrades. I have all the parts and
materials loaded in an older version. I have been asked to use a newer
version, which I have not done and will not do until it is absolutely
required, because I do not want to recreate all the materials in the new
software. Perhaps it can be copied onto the new version, but I tried that
and failed. I do not have the spare time to mess with it so I did not
continue.
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 probably
would have taken 15 – 30 minutes to input the data, create materials, etc.
• What suggestions and improvements do you recommend? If
companies want their suppliers to use this software they need to keep it
stable. It is very time consuming using it when you consider all the parts for
which data has to be entered every month, year, etc. To have to update
previously input data is asking too much. To minimize the cost impact on
suppliers, software like this should be developed for use by admin level
people and should not require a college degree, eg engineering. I do not
believe that is the case now.
• What barriers do you see in adopting the tool across your company? I
do not know what you mean by “adopting the tool across your company.”
But if you mean having many people in our company supplying data to
customers using Compliance Connect, it is too time consuming and
therefore expensive. It has to be used by one or a few people, who
maintain a high level of competence with it. Now I am the only person who
uses it in my company, and I cannot find anyone to unload it onto. It is an
accident of history that I am doing this.
Supplier X - Compliance Connect
•
•
•
•
How many times have you used this tool? Three times,
once each for Motorola Northbrook Il , Schaumberg Il and
World Wide Strategic Sourcing and Supply Management,
Personal Communications Sector
How easy or difficult was the tool to use? It was fairly
easy even for an untrained person such as myself. Each
time easier as I became more familiar with the document.
What was your experience during the installation (if
applicable, positives and negatives)? I essentially filled
out paper copies only as this is what I was given by others
in our organization.
What was your experience during the data entry
process (positives and negatives)? I feel that due to the
fact we only supply aluminum alloy parts that the
information is repeated un-necessarily
Supplier 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 very
labor intensive and because of the macros used in the program,
data cannot be copied into the spreadsheet from another
database 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 where
ready 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 the
instructions are but they make it difficult to import data from
another source. We realize this is because one generic form is
used for all commodities, but it is quite tedious and labor intensive
to enter the data.
•
What was your experience during the reporting / data
exchange (positives and negatives)? Easy output to CXS file.
Submission is electronic so this is easy.
Product Aggregation and Reporting - Process Flow
Dynamically View Bill of Materials
ERP
PLM
Excel
Flat File
Search by Customer or Internal Number
Complete or Selective Aggregation
Multiple Sourcing Engine
Material Aggregation & Worst Case Analysis
Full Disclosure Enabled Reporting
Data Exchange Protocols
•Compliance Connect
•RosettaNet
•IMDS
•Custom Format
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 material
content, and
– review product material content aggregated at
top level
• Worst case analysis for multi-sourced parts
Reporting and Compliance Status Report
Reporting and Compliance Status Report
Product Reports
• Refer to Excel Component by Component
report
• Refer to Excel Top Level Aggregated
Product Report
Product Report
EMARS allows Selective or Complete Aggregation
Product Report
Worst Case Analysis
Supplier A
Supplier B
and supports multiple sourcing of parts
Component Material Content Report
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 from
manufacturers 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 substance
list as JIG Annex A.
Compliance with internal requirements? Customer
requirements? Current regulations?
– EMARS was designed to comply with Motorola’s internal
requirements and with all its current customer and regulatory
requirements in both the automotive and electronics industries.
Response to Pilot Questions, cont’d
• How accurate are the results? How was data
integrity 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 by
suppliers.
• Data is then reviewed and processed by a technical expert
prior to upload.
• The upload utility further verifies that the data complies with
the necessary parameters for it to load into Motorola’s
system.
– In addition, product aggregation reports and worstcase analysis calculations were validated by
scientists at Motorola Labs.
– Worst case analysis reports also present tolerance
percentages for each value.
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 already
installed and running at our company.
– The implementation of EMARS allowed for a 90%
reduction in the time and effort invested to complete
and 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
EMARS Part Functionality
Supplier Part Functionality
Search by
Supplier or Motorola Part Number
Compliance Status
Supplier (Name or ID)
Date Material Declaration Received
Controlled Substance
Part Compliance
View Material Breakdown
Calculate/view Compliance Status for Multiple
Standards
View Compliance Report
Support for Compliance Exemptions
Notifications
Notify when new part data is added
Notify prior to exemption expiration
EMARS Comments
r
r
r
r
r
r
r
r
r
r
r
Not Appliable to Pilot
EMARS Product Functionality
Product Reporting Functionality
Search by
Motorola or Customer Part Number
Customer
Product Information
Retrive BOM Data from existing Systems
View Product Reporting History
View Single Level BOM Rollup
View Multi Level BOM Rollup
View Compliance Status for each item on the BOM
Product Aggregation
Complete or Selective Aggregation
Worst case analysis for multi-sourced items
Report per multiple standards/data formats
EMARS Comments
r
r
r
r
r
r
r
r
r
r
Single system used for pilot.
N/A for pilot
Summary of Pilot Results
• Pilot test process completed successfully and
with no issues
• Parts compliance status assessed against
Motorola/JIG standards
• Reports generate both at component and
product level
• All major reporting features are available in
EMARS tool to support Motorola’s business
needs
• EMARS integrates with existing engineering and
manufacturing infrastructure. No need for data
migration or recurring updates of another
database.

NEMI Material Declaration Pilot Motorola Results

Transcription

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