NEMI Material Declaration Pilot Motorola Results -...

February 2004. © Motorola All rights reserved.

NEMI Material Declaration PilotMotorola Results - EMARSTM


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


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 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


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


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


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


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


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


Part Compliance Evaluation


Part Compliance - Status Report


Compliance Specification Report


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


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.



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.



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.


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 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


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.


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


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


Reporting and Compliance Status Report


Product Reports

• Refer to Excel Component by Componentreport

• Refer to Excel Top Level AggregatedProduct Report


Product Report

EMARS allows Selective or Complete Aggregation


Product Report

and supports multiple sourcing of parts

Worst Case AnalysisWorst Case AnalysisSupplier A Supplier B


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 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.


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.


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


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


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


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.

NEMI Material Declaration Pilot Motorola Results -...

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