Post on 08-Feb-2016
description
If It Moves, Scan It!The Sugar Foods Story
Kerry White, Sugar FoodsRay Agrusti, Eagle Global Services
QAD Proprietary
SUGAR FOODS PRODUCTS ARE
CONSUMED80 MILLION TIMES
PER DAY!
#1 Supplier of sugar substitutes
#1 Supplier of powdered, non-dairy creamer
#1 Supplier of almonds
#1 Supplier of croutons and crunchy salad toppings
QAD Proprietary
SUGAR FOODS PRODUCTS ARE DISTRIBUTED TO MORE THAN
850,000 OPERATORS
Commercial Food Service Providers
Non-Commercial Food Service Providers
• Restaurants
• Hotels
• Colleges
• Health Care Facilities
Retail and Consumer
• Warehouse clubs
• Supermarkets
• Mass merchandisers
QAD Proprietary
Sugar Foods operates four manufacturing facilities, with another coming on-line later in 2008.
Bakery items
Takes sales orders; Produces dry items,
condiment type
Bakery and dry items
QAD Proprietary
Manufacturing Manufacturing in 4 Locations:
– Sun Valley, CA– Villa Rica, GA– Commerce, CA– Mazatlan, Mexico
Service the following markets: – Foodservice– Specialty Markets
• Office Coffee Services (OCS)• Vending• Convenience Stores• Membership Warehouse Clubs
– Retail– Mexico– and Beyond!
Sun Valley, CA (180,000 sq. ft.)(5 football fields)
Commerce, CA (250,000 sq. ft.)(7 football fields)
Villa Rica, GA (340,000 sq ft.)
(10 football fields)
Mazatlan, Mexico (70,000 sq. ft.)
(1.5 football fields)
QAD Proprietary
Challenges
Less than acceptable inventory accuracyMaximize efficiency and profitabilityLimited granularity in transaction historyUnidentifiable products with similar
characteristicsMeet compliance requirements for lot traceabilityPosition for future growth
QAD Proprietary
Meeting the Challenges: Phase 1
Implemented QAD Eb2.1in 2006– QAD recognized Sugar Foods with its “Rapid
Implementation Award” at Explore 2007– Discovery to GO-LIVE in 77 days
QAD Proprietary
Known Challenges – Specific to ADC
Inventory accuracy or a single location called “OT”• Inventory that’s “Out There” somewhere
Real-time information Elimination of manual logging of raw materials Track materials from receiving through production and
then shipping by means of an automated system that provides full lot traceability
QAD Proprietary
The Right Solution for Sugar Foods
Sugar Foods chose Eagle’s RF Express™ for QAD Enterprise Applications
Chose Intermec Corporation’s CK31 RF handheld devices
Chose Zebra Technologies 105SL bar code label printers for the shop floor
QAD Proprietary
Why Eagle?
Strategic QAD Partner since 1992Seamless integration with QAD EAProgress-based solution99% data accuracy or betterReal-time data capture without changes to QAD
codePersonal experience with Eagle’s solution– Ease of implementation and use– Hardware and device flexibility
QAD Proprietary
Phase 2: Leveraging QAD EAwith an Automated Data Collection Solution
“ERP system implementations have 50% higher benefits when integrated with an Automated Data Collection System.”
Gartner Group 2001
Began ADC of raw material data in Villa Rica facility in July 2007– Receiving– Material transfer– WIP production
Completed rollout of raw material in Sun Valley in September 2007
Completed rollout of raw material in Commerce in December 2007
QAD Proprietary
HOW DID WE DO IT? Made early determination that all items should be
tracked utilizing pallet ID’s with very few exceptions
Identified data that should be visible and scanable on all items (Label Definitions)
Identified material flow and drop-off/storage locations
Identified QAD transactions required to achieve maximum efficiency and traceability
Identified Eagle transactions
Labeled all possible storage locations (racks, floor, trailers, etc.)
Performed repetitious hands-on training with users
QAD Proprietary
FG InventoryLocations
Receiving
RM InventoryLocations
MaterialTransfer
RM InventoryLocations
Manufacturing ProductionScanning
ProductionStaging Locations
RM Hoppers
PORPOMPOB
PTRTRN
PTRTRN
PDPTDPPTR
BKF
MaterialTransfer
PTR
EAGLE RF EXPRESS for QAD EA
AUTOMATED DATA COLLECTION SYSTEM
PROCESS FLOW DIAGRAM
Status/Expire Date ChangeLabel
Printing
PLBLBL
PSCIDM
PRVIBIIBL
PRVIBIIBL
PRVIBIIBL
Receiving
Material Handling
Production/Finished Good Inventory
Order Picking/Shipping
PPKPICSPK(PL)SLBPGN
UtilitiesIBIIBLSBIPRVPLOCNTCTICTRTCTTRCUNRUNIBCPBCV
QAD Proprietary
Receiving
RM InventoryLocations
MaterialTransfer
RM InventoryLocations
ProductionStaging Locations
PORPOMPOB
PMVTRN
PMVTRNPDL
PRVIBIIBL
PRVIBIIBL
Receiving
UtilitiesIBIIBLSBIPRVPLOPDLCNTCTICTRTCTTRCUNRUNIBCPBCV
EAGLE RF EXPRESSFor QAD EA
AUTOMATED DATA COLLECTION SYSTEM
PROCESS FLOW DIAGRAM(SUPPLY CHAIN)
Material HandlingLabelPrinting
PLBLBL
QAD Proprietary
EAGLE RF EXPRESS for QAD EA
AUTOMATED DATA COLLECTION SYSTEM
PROCESS FLOW DIAGRAM(Production)
Manufacturing ProductionScanning
ProductionStaging Locations
RM Hoppers
PDLPLO
BKF
LabelPrinting
PLBLBL
Material Handling
UtilitiesIBIIBLSBIPRVPLOPDLCNTCTICTRTCTTRCUNRUNIBCPBCV
QAD Proprietary
KEYS TO SUCCESS? “Know the Flow”
Simplify the process
Provide as many tools as necessary
Reduce keypad entry
Review the process periodically
QAD Proprietary
Where do we go from here? Implement scanning of finished goods w/lot control
– Production recording using backflush transaction– Pallet transfer between inventory locations– Sales order picking & shipping
Inter-company transfers utilizing DRP
Meet specialized customer labeling requirements– UCC/EAN 128 labeling– RFID labeling– Link to ASN transaction
Implement all scanning functionality in Mazatlan facility
Turn on lot control for raw materials
QAD Proprietary
Kerry WhiteIT Manager, Villa Rica FacilitySugar Foods Corporation+1.770.459.5225+1.770.459.9863 (fax)KWhite@SugarFoods.com www.SugarFoods.com
Contact Information
Ray AgrustiSenior Product Consultant / Project ManagerEagle Global Services+1.973.838.5006+1.973.492.2758 (fax)RAgrusti@EagleConDev.com www.EagleConDev.com
RF Express™ for QAD Enterprise Applications is a trademark ofEagle Consulting and Development.
“QAD” is a registered trademark of QAD Inc.
All other products or Company names herein may be trademarks of their respective owners.