Production

Production is typically the most important and most complex process in a manufacturing company. It is where the majority of any added value is generated. However, if we seek to maximise it, production needs to be efficient, manageable, controllable and planned.

Product structures and practices are a necessary input for production planning and management. QAD also supports sub-assemblies that may also be used in more than one finished end product. It uses standardised data to calculate product costs and then applies cost deviations to indicate the differences between planned and actual figures

QAD supports a variety of manufacturing types and their combinations
Do you produce or even develop custom products? Then your enterprise system must be integrated with the tools of your development department. QAD TPV Plus shares information with CAD/PLM/PDM systems to simplify the work of process engineers. QAD plans and manages production using work orders that record revenues, expenses, labour and non-conformities. Production can be managed on a paperless basis with records being automated by interconnecting machines through QAD’s integrated MES system

Do you use production lines, or do you need to organise assembly? QAD promotes production line scheduling optimisation with an emphasis on efficiency. Materials are fed to each line using generated loading lists with production records being updated accordingly. The lines can also be managed with manufactured products being read via the integrated MES system
Do you use repetitive production and wish to save redundant operations and records? QAD supports lean manufacturing with both electronic and physical KANBAN. Production is managed by action signals with records created and updated by simply scanning the KANBAN cards

QAD TPV Plus

Drawings, manufactured items and BOMs are created by the R&D Department in CAD/PLM/PDM systems. Purchased materials are managed by purchasers in the enterprise system. There is nothing worse than these two systems failing to communicate with one another. TPV Plus ensures efficient cooperation and data sharing among all processes within these systems while increasing the level of convenience for process engineers when creating work procedures.

With QAD TPV Plus, you get:

Reduced development and production preparation time
Time savings for process engineers that create BOMs and procedures
Streamlined communication between the development department, process engineers and production

Features

The material code list is maintained by the purchaser and provided to the developers’ tools for use in BOMs
Developers create new production items in their systems, creating drawings, models, and BOMs
The production items and BOMs are then sent to QAD TPV Plus where a process engineer can modify the design BOMs into production ones
The process engineer then creates work procedures using industry standards to calculate the production times of the operations
Change management is simplified as all business processes are interlinked within the enterprise

QAD MES

Production digitalisation or Industry 4.0 are the drivers that move manufacturing towards ever-greater automation and gradual replacement of people with machines and intelligent systems. If you want to integrate an enterprise system with machines, you could implement a dedicated third-party MES. However, to what degree will this lead to duplicate data in the enterprise and MES system? How do you ensure efficient communication between them? Who is going to be responsible for the MES system including long-term support? What will be the overall cost? Minerva offers MES as a part of the QAD Enterprise System.

With QAD MES, you get:

Reduced costs and time savings in organising production resulting from improved communication between the enterprise system and machines
Accurate, real-time records of actual levels of materials used, labour and machine time

Features

Everything is integrated into a single package:
- The production plan is provided by QAD MRPII with a more detailed schedule for individual machine resources for production management being provided by Preactor APS by Siemens (where required)
- The processes and BOMs required for production control are managed by QAD
- The manufacturing machine resources are managed by QAD including their preventive and operational maintenance
- QAD uses the MES module to communicate with all relevant machine resources and collect data directly from the workstations
- QAD provides the product production history and batch traceability information
- QAD provides analyses and indicators, such as OEE
QAD supports the replacement of discontinued products with up to date ones
The material supplied is scanned and recorded by warehouse personnel using RF terminals
We will install kiosks in the plant to show work queues per workstation and to record actual production figures

The kiosks also allow the operator to enter any relevant quality control data (operator ID, non-conformances, corrections of the values read, measured values, etc.) via scanning or touchscreen.
QAD evaluates actual production efficiency against predefined target levels and visualises OEE and other indicators
Weighing system integration for weighing-in and reading quantities
Measuring device integration for loading test results
Support for sheet metal flame cutting optimisation - integration with Radan, SAPS, WRykRys, Trumpf TruTops SW
Support for laser cutting - integration with JetCAM, Trumpf
Communication with the TruTops FAB sheet metal handling automation system
Integration with MOTOMAN and CLOOS robots
Integration with the Tulus and Prima Power press MES
Use of QR, barcodes, RFID, cameras and voice communication, forklift control, Kardex warehouses – see QAD Managed Warehouse. QAD Managed Warehouse.

QAD Redzone Connected Workforce

Unlock the power of your frontline teams.

QAD Redzone delivers

29% productivity increase
74% increase in engagement
32% reduction in staff turnover

Key Challenges

Labor Shortage – incoming workforce has different interests
Turnover – average tenure is shrinking and experience is leaving
Wage Wars – at some point, the costs outweigh the benefits
Inflation – reduced margins are an additional barrier to growth

Capabilities

Collaboration
Huddle around real-time data to focus on the right problems, conduct root cause analysis, implement actions, and connect your frontline team to plant leadership to remove barriers and solve problems.
Productivity
Identify systemic problems, empower frontline teams to leverage technology and data for problem solving, and implement high-impact improvements with closed-loop tracking.
Compliance
Inspect for safety and compliance, conduct weighted audits, and ensure all process tasks are completed with configurable checklists.

Reliability
Maximize equipment health and productivity by equipping operators to perform the first line of care, removing tension with maintenance and preventing downtime.
Learning
Provide every worker with training and skills through video recordings easily made by your own expert workers. Ensure new skills are quickly acquired and tracked through digital skill matrices, learning packs, and on-demand mentoring.

QAD Redzone

Our Connected Workforce solution is centered on Collaboration, Productivity, Compliance, Reliability, and Learning. The SaaS product also offers extended capabilities for enterprises to capture every possible benefit:

Integrations

Developer Hub – Interactive API documentation (OpenAPI), examples for common tasks, and copy-paste code examples.
Authentication – Access our systems seamlessly using your existing identity provider, and enhance with role-based access control (RBAC).
Analytics – Our solution includes out-of-the-box intelligence and enables connections with your own data warehouses.
Command Line Interface – Redzone’s CLI enables you to call Redzone directly from your existing scripts and automation tooling.

Coaching

90 Days – Results are delivered within 90 days of implementation through frontline coaching programs that deliver fast adoption and worker enthusiasm.
New Skills – Our coaches are on the floor with your workers, ensuring new behaviors become second nature habits that stick beyond 90 days.
Transformations – Redzone brings out the best in your own people, empowering your natural problem solvers to drive improvement.

ESG

Environmental – Increased productivity and paperless operations enable you to do more while spending less (natural resources and money).
Social – Provide lasting manufacturing jobs that promote individual safety and satisfaction while providing economic strength in your local communities.
Governance – Digitized audits and checklists embed compliance into everyday operations.

ADC – barcodes, RFID

ADC is an extension program for selected QAD modules. It increases data entry productivity by reading barcodes or RFID chips which simplifies the process of obtaining user information. Its primary use is in distribution and storage processes, but it can also be applicable in other repetitive production processes. ADC is available in the following QAD ERP processes:

With ADC you can:

Eliminate the following problems and enable:
- Immediate entry of current data in the system
- Immediate checks on the correctness of the data
- Removal the need for paper media
Simplify data entry procedures that are crucial for manufacturing system performance monitoring. The conventional way is too costly, overly complicated or difficult to process in a workshop or office environment
Avoid delays and erroneous entries caused by conventional paper-based data collection procedures

Features

ADC supports two basic methods of inventory monitoring:
- Standard QAD: Location, SM, Article, Series/Batch, Reference
- Pallet label, PJ number and rack position
Low time intensity

Zero errors
Removes the delay between actual location data and its entry in the information system
Current and complete inventory level information

Project Management

Project Management manages project or custom manufacturing which is significantly different from conventional types of manufacturing.

With Project Management, you get:

Full integration of the materials flow and accounting process
Transfer of raw materials and products to stock for a specific project on time so they can be used to implement the project. A budget is created for the project and QAD recognises all the facts for the project
Project information is accessible, even for senior management, in the form of graphical representations of the production process and includes metrics to enable early identification of any problems along with their causes