QAD Training MWUG Slides September 2015 Jackie Das (The Tech - - PowerPoint PPT Presentation

QAD Training MWUG Slides

September 2015 Jackie Das (The Tech Group) Andrew Hall (Logan Consulting)

Tech Group Confidential

• Project Manager at the Tech Group
• Finance background
• 4 years ago, I was asked to lead a project to upgrade

QAD to 2011 SE across all 9 sites.

• Since then, worked on QAD training, implementation

and improvement projects, and IT projects

Intro – Jackie Das

• Nine Manufacturing Sites using QAD
• 1,000,000 square feet of mfg. space
• $275MM in Sales/1,500 employees
• A division of West Pharmaceutical Services,
• Inc, a $1.4bn company
• Competencies:
• Product Development
• Injection Molding
• Contract Assembly
• Finished Packaging

The Tech Group

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“A process driven, full service developer and manufacturer of components & devices for the healthcare industry”

7

Arizona (4)

Pennsylvania

Ireland

Denmark

Manufacturing Sites Development Centers

Michigan Puerto Rico Indiana

Manufacturing Footprint

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Markets Served

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Pharmaceutical

Devices & Final Packaging Pulmonary & Injectables

Diagnostics

Components, Kits & Packaging Molecular & Point of Care

Medical Care

Components & Assemblies Ophthalmic, Ambulatory, Surgical

Consumer

Components & Assemblies Personal Care & OTC Packaging

QAD/MfgPro User since 1988

NetUI ChUI Eagle Mercury Cyberquery Version: 2011 SE

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• Share with you our training program ‘journey’ at The

Tech Group

• Review some of the challenges and how we are working

through them

• Answer your questions

Today’s goal

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1988 QAD/MfgPro implemented 2012/2013 Upgraded to 2011 SE Training program implemented

Evolution of QAD training/improvement program

2015 and Beyond Training program continues *No ‘formal’ training*

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• 1. Trust in ERP system/Poor quality data
• 2. No defined training program
• 3. Business Processes not defined/standardized
• 4. No baseline understanding of APICS and ERP

concepts

• 5. Not using all ERP functionality/working outside the

system

• 6. Reporting difficulties/visibility across sites
• 7. No champion/no strategy
• 8. No ‘go to’ for training

Problems we faced:

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• What we were hearing:
• “The system won’t allow us to do that…”
• “The system is crap….”
• “We don’t trust the reports…..”
• “ I don’t use MRP because it’s wrong…” “The MRP

reports are so long I can’t find what I’m looking for…”

• “The inventory balances in the system are off, I’m

better off walking the floor to see where my stuff is at”

#1:Trust in the system/Poor quality data

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• What we did:
• Train people on the meaning of the various data fields

and how they impact processes and reports.

• Week long ‘workshop’ to agree how all the sites would

use use key data fields

• Began “cleaning up” the data
• Examples:
• Planning data
• Archiving

#1:Trust in the system/Poor quality data

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• What we used to do:

#2:No defined training program:

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• What we do now:
• All new hires go through formal training
• Online training videos (learning portal) on SharePoint site

#2:No defined training program:

#3:Business Processes not defined/Standardized:

Manufacturing is challenging!

QAD impacts everything we do and can be confusing.

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• Agreed ‘best practice’ processes across all sites – week

long workshop held in 2014

• These form the basis of training

#3:Processes not defined/standardized

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What we had before:

• People understand only the transactional piece of their job
• No understanding of why their piece is important
• People feeling isolated.
• Acronyms and terminology not understood

#4:No baseline understanding of APICS and ERP concepts

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What we have now:

• Understanding in the business of how what people do impacts

the upstream and downstream processes.

#4:No baseline understanding of APICS and ERP concepts

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• Developed a 3 day training (not hands on in QAD) to teach

concepts

• Lego game to demonstrate:
• BOM
• Inventory control
• MRP
• Costing
• Forecasting
• Variances
• Formal APICS training
• Plan to take the 3 day training and make it “hands on”

#4: No baseline understanding of APICS and ERP concepts:

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• Trained over 100 people
• Went to all the sites
• Measured results – quiz before and after class
• Published glossary of terms

#4: No baseline understanding of APICS and ERP concepts:

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• What we had before:

#5:Not using all ERP functionality/working outside the system:

And th

#5:Not using all ERP functionality/working outside the system:

Manual Systems Spreadsheet overload Guessing games

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• MRP in use at most plants
• Planning and Scheduling Workbenches implemented by

end of 2015

• Forecasting
• GRS (Global Requisitioning System)
• EAM (Enterprise Asset Management)
• Fixed Asset Module implemented in Europe

#5:Not using all ERP functionality/working outside the system:

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• What we had:
• Unable to readily access data for consolidated reports
• Hunting and pecking for information we needed
• Reliance on other people
• What we have now
• Browses and browse collections
• Cyberquery
• 60 people across the company trained
• Puts the power in their hands

#6:Reporting Difficulties/Visibility across sites

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• ERP Excellence Director
• ERP Excellence Team:
• Project Manager
• IT Business Analyst
• Supported by top management
• Expected to deliver measurable results
• Central resource for training
• Coordinated approach to training

#7 & #8:No Champion/No Strategy - No “go to” for Training

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• No quick fix!
• No easy button
• Not a one year project, not a 5 year project….
• Multi year project

Time Frame Alert!!

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• Remember the 3 P’s – People, Process, Platform
• Get a Corporate Sponsor(s)
• Training doesn’t belong in IT
• Peer pressure is a great thing!
• Right people/right time – MSW/PSW is a case in point
• Start with the end in mind
• Make training interesting
• Keep the momentum going
• Don’t get discouraged!

Final words….Lessons learned

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Questions

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• Jackie Das – 480 213 0353 jackie.das@westpharma.com

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