Roll Stock and Wire Cable

Benefits

Optimize inventory by improving collaboration between planning and execution teams

Increase customer responsiveness by deploying alternative schedules in real time

Digitize management of customer and supplier orders through EDI

Eliminate issue root causes with centralized visibility and integrated quality

QAD provides a unique solution for roll stock and wire cable manufacturers that supports collaboration across planning, manufacturing operations, quality and customer service. The solution requires minimal configuration and may be deployed in the cloud and on premise. Several leading manufacturers successfully utilize the QAD solution as the foundation to continuously improve effectiveness.

Roll Stock and Wire Cable Manufacturing Value Chain

In the value chain, certain products are delivered in standard formats to many different customers. Other products are collaboratively provided to specific manufacturers and OEMs that desire customization. These consumption and production differences affect the channels for product delivery and customer interaction. The QAD solution consists of the full-featured QAD Cloud ERP and related capabilities that include global financials, planning and scheduling workbench, shop floor data collection, demand and supply chain planning and quality management. QAD right-sized the solution specifically for a production environments with high mix of make-to-order and make-to-stock products.

Reduce Sales, General and Administrative expense and Cost of Goods Sold while improving Operating Income Margin through more effective planning and scheduling

Improve Delivery In Full On Time (DIFOT), Forecast Accuracy and Inventory Accuracy while reducing Stock-outs with more accurate demand planning

Enhance Supplier Performance, CAPA Efficiency and GMP Compliance with fully integrated quality management

Reduce Work-in-Process and Finished Goods Inventory through collaborative management of planning and operational activities

Roll Stock and Wire Cable Solution Overview

Roll stock and wire manufacturers must produce uniform material quality at the exact physical dimensions which is critical to managing profitability in an industry with tight margins. Operational effectiveness is essential to manage material costs, coordinate production schedules, align with quality expectations and exceed customer service levels. Manufacturers must address competitive pressure to deliver new permutations which condense product life cycles. Other barriers to success include:

Untapped capacity is a lost order − every nonproductive hour of machine utilization could be turned into servicing another customer order.

Excessive raw material and finished goods inventory levels impact cash flow and inhibit investment.

Underperformance on client deliveries – DIFOT − affects the manufacturer’s ability to grow with key customers and restricts the pursuit of new customers.

Operational effectiveness is imperative under these conditions. Market share increase and improved customer support, however, cannot be achieved by limiting investment. The successful roll stock and wire cable manufacturer needs to operate as a collaborative entity at peak effectiveness and maintain a sharp focus on the following three areas:

  1. Quality: Effective organizations have an automated quality management system that allows them to apply quality principles from design and engineering through final customer delivery and support.
  2. Delivery: Roll stock and wire cable producers must deliver 100 percent on-time and therefore must excel in automatically integrating customer requirements into ERP. Successful manufacturers leverage ERP to automatically schedule the shop floor and minimize the use of manual systems or spreadsheets.
  3. Operations: Effective roll stock and wire cable organizations must optimize their operations by focusing on quality, cost and delivery.

The QAD solution for roll stock and cable manufacturers provides end-to-end capabilities that can be flexibly deployed to support rapid expansion and adoption. Some key capabilities of the QAD solution include:

Planning and Scheduling Workbenches

QAD QMS (Quality Management System)

QAD Automation Solutions – Material Handling, Shop Floor Data Collection and Label Printing

QAD DSCP (Demand and Supply Chain Planning)

Internationalization

QAD BI (Business Intelligence)

An overview of the first three critical capabilities follows. For information about the other processes, please visit QAD.com.

Planning and Scheduling Workbenches

QAD’s Planning and Scheduling Workbenches generates more reliable production plans, makes it easy to manage exceptions proactively and respond to changing conditions. Improving production plans positively impacts the Manufacturing Schedule, Manufacturing Efficiency, Asset Utilization and Inventory Effectiveness metrics.

Planning and Scheduling Workbenches give schedulers total visibility of demand, supply, inventory, capacity and production using an intuitive spreadsheet-like workbench. Schedulers have visibility into planned production, alternative resources, customer demand changes, inventory levels, safety stock, sales forecast, production capacity and planned maintenance schedules. Schedulers interact directly with the schedule, with color-coded alerts that focus attention on potential issues. 

Planning and Scheduling Workbenches

QAD QMS (Quality Management System)

Roll stock and wire cable manufacturers commit significant resources to sustain product quality. An automated quality management system is often critical to track and meet customer and regulatory requirements. QAD QMS helps address key performance indicators like Complaint Tracking and Supplier Performance and measures like CAPA Efficiency, Open Complaints and Lot Acceptance Rate. QAD QMS modules include:

Auditing management helps management assure that well-defined business processes apply throughout supply chains and generate the results expected. When processes are not meeting expectations, the initiation of corrective actions ensures that any problems are resolved and operations quickly return to normal.

Document control helps manufacturers manage critical documents like Standard Operating Procedures (SOP) that are stored in a centralized repository and that work with automated workflows to ensure compliance. Built-in controls ensure that document changes also update related procedures and initiate retraining.

Corrective Action Preventative Action (CAPA) and Nonconformance Reporting (NCR) provides an automated closed-loop solution for problem tracking and resolution, including impact on other processes or products.

Training management tracks each employee, each role, skills associated with that role and training requirements for those skills. Training may be recurring, competency-based or required due to a controlled document change.

Risk management enables organizations to define and prioritize each risk, create a heat map and a mitigation plan with related action items and reporting, helping manufacturers with managing a comprehensive set of risk requirements.

Supplier management helps to evaluate and select suppliers based on their ability to supply product in accordance with requirements. Supplier performance improves when suppliers are consistently evaluated, monitored and measured. 

QAD QMS Supplier Management Dashboard

QAD Automation Solutions

QAD Automation Solutions improves manufacturers’ material transactional effectiveness by aligning ERP with material processes. The two primary components are:

Data Collection captures material and production data through simplified ERP transactions using a mobile device such as a radio frequency (RF) scanner, tablet or a stationary shop floor personal computer or terminal.

Label Printing Services routes and prints labels associated with material and production transactions based on manufacturer, supplier and customer formats and rules. The services support any label format and any printer and are GS1 and 2D compliant.

Automation Solutions acts as a highly configurable set of capabilities that requires no coding for a wide variety of manufacturing environments, specifically:

Transaction Development Toolset reduces customizations by simplifying the development of material and production transactions through configuration of the QAD Service Interface.

Transaction Library provides out-of-the-box transactions for inbound, outbound, production, inventory management and packaging for ERP functionality. The library extends to QAD Enterprise Asset Management.

Transaction Processing Engine ensures failure free transaction processing through QAD core SIAPI processing and interactive record locking management.

Transaction Linking combines multiple transactions to create a unified and simplified transaction, aligning with material handling and production processes.

Label Mapping/Routing Toolset easily maps to QAD material and production data to select the right label format and to print to the correct printer. 

Automation Solutions Integrate Data Collection and Label Printing

For more information on how the QAD roll stock and wire cable manufacturing solution can help your company, please contact QAD at +1-805-566-6100 or email info@qad.com.