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A Partner Connect Webinar
Integrated Best-in-Breed Project Manufacturing SolutionsPaul Whiteman
October 1, 2019
A Partner Connect Webinar
Paul WhitemanPartner
Lexell Blue, LLC
Speaker
CONFIDENTIAL © Deltek, Inc. All Rights Reserved. 2
Lexell Blue Services
CONFIDENTIAL © Deltek, Inc. All Rights Reserved. 3
» Costpoint/TESS Implementations and Re-Implementations
» Costpoint Materials/Manufacturing
» Data Migration, Restructures, M&A Integration and Divestitures
» Cognos Report development
» Product Installations, Upgrades & O&M
» Costpoint Health Check/Product Usage Assessments
» Project Management
Agenda» Introduction
» ‘Best in Breed’ manufacturing systems
» Manufacturing maturity and integration
» ERP – PLM
» ERP – MES
» ERP – QMS
» ERP – Shop Floor Labor
» ERP – APS
» Implementing integrated systems
» Summary
4
How to control the chaos?
5
Project Manufacturing Life Cycle Business Processes
6
‘Best in Breed’ Systems
7
Product Lifecycle Management
(PLM)
Manufacturing Execution (MES)
Quality Management
System (QMS)
Capacity Planning & Scheduling
(APS)
Shop Floor Labor
Materials Requirements
Planning (MRP)
Enterprise Resource
Management (ERP)
‘Best in Breed’ Concepts» Leverage rich capability of purpose built tools within your industry, business model and
product set
» Aerospace & Defense Federal Contracting
» Engineer/Build to Order
» Build to Print
» Complex/Discrete Manufacturing
» Leverage the knowledge base of vendors and consultants focused on your industry to provide Industry Best Practices
» Leverage Integration and Automation technologies to connect systems
8
Compliance
9
» DFARS Business Systems
» Accounting
» Materials Management Accounting System (MMAS)
» Purchasing (CPSR)
» Property
DFAR 252.242-7004 Material Management Accounting System.As prescribed in 242.7204, use the following clause:MATERIAL MANAGEMENT AND ACCOUNTING SYSTEM (JUL 2009)(b) General. The Contractor shall—(1) Maintain an MMAS that—(i) Reasonably forecasts mate
ii) Ensure(iii) Maintains a
(2) Assess its MMAS and take reasonable action to comply with the .(c) Disclosure and maintenance requirements. The Contractor shall—
(1) Have policies, procedures, and operating instructions that adequately
(2) Provide to the Administrative Contracting Officer (ACO), upon request, t
(3) Disclose significant changes in its MMAS to the ACO at least 30 days prior to(d) Deficiencies.(1) If the Contractor receives a report from the ACO that identifies any deficiencies in :
Compliance
10
» Product Traceability
» Quality
» CDRL – Contract Data Requirements List
DFAR 252.242-7004 Material Management Accounting System.As prescribed in 242.7204, use the following clause:MATERIAL MANAGEMENT AND ACCOUNTING SYSTEM (JUL 2009)(b) General. The Contractor shall—(1) Maintain an MMAS that—(i) Reasonably forecasts mate
ii) Ensure(iii) Maintains a
(2) Assess its MMAS and take reasonable action to comply with the .(c) Disclosure and maintenance requirements. The Contractor shall—
(1) Have policies, procedures, and operating instructions that adequately
(2) Provide to the Administrative Contracting Officer (ACO), upon request, t
(3) Disclose significant changes in its MMAS to the ACO at least 30 days prior to(d) Deficiencies.(1) If the Contractor receives a report from the ACO that identifies any deficiencies in :
Manufacturing Maturity
11Solution Sophistication
Man
ufac
turin
g M
atur
ity
Procurement
Product Definition
InventoryManagement
Bills of Materials
Production WIP Control
Sales Orders
Routings
BarcodingECN
MRP
MPS
APSCapacity Planning
MES
Shop Floor Labor
QMS
Integration & Automation
PLM
Impacts to Manufacturing Maturity
» Product lifecycle stages
» R&D Research & Development
» LRIP Low Rate Initial Production
» FRP Full Rate Production
» Business size
» Management / Leadership
» Staff / Resource turnover
12
ERP - MRP
13
Materials Requirements
Planning (MRP)
Project Financials (ERP)
» Your Supply Chain and MRP needs to be tightly connected to your financial/billing system – compliance risks
» MRP systems integrated to Financial Systems is not typical or recommended
» Difficulties tracing costs from source through to financial reporting and billing
» Choose a system that will provide project financial compliance and project based MRP
PO’sReceiptsJournal Entries
ERP / MRP - Project Financials- Procurement- Inventory- Production Control- MRP
ProjectsSuppliers
Parts
Bills of Material Management
14
Key questions that need to be answered:
» What system owns the Part maintenance?
» What system owns the MBOM? PLM, ERP or MES
» How will you compare BOMs?
» What system will record the As-Built Configuration?
As-Proposed As-Designed As-Planned As-Built As-Maintained
PBOMProposal
Bill of Material
EBOMEngineering
Bill of Material
MBOMManufacturing Bill of Material
As-BuiltBill of Material
As-Maintained
Bill of Material
ERP – PLM/PDM
15
ERP / MRP
PLM / PDM
VendorsManufacturersCommodity Codes
PartsEBOM or MBOM
Engineering ChangesBOM Revisions
» Product Lifecycle Management (PLM) provides:
» Managing product changes through design, development through to obsolescence
» BOM Configuration Management
» Product Data Management (PDM)
ERP – PLM/PDM
16
ERP / MRP
PLM / PDM
VendorsManufacturersCommodity Codes
PartsEBOM or MBOM
Engineering ChangesBOM Revisions
» Historically data transferred was limited to Parts and BOMs, with ECN’s manually replicated
» Integrating ECN’s from initiation through to implementation provides supply chain impacts
ERP – MES
17
MES
ERP / MRP
Basic RoutingsWork Order UpdatesWork Order Completions
PartsCharge Number
MBOMWork Centers
OperationsWork Orders
Warehouse LocationsWork Order Issues
» Manufacturing Execution System (MES) provides:» Process Planning and Execution» Paperless Work Instructions» Data Collections» As-Built Configuration
» Most ERP/MRP systems are ‘light’ on MES» The shop floor finally goes ‘paperless’
ERP – QMS
18
QMS
ERP / MRP
QC InspectionsVendor Status
PartsCharge Number
VendorsPO / ReceiptsWork Orders
» Quality Management System (QMS) provides:» Non-conformance tracking» Inspection planning and execution» CAPA» Quality metrics/reporting» Tool/Gauge management» Vendor performance
» Most ERP/MRP systems are ‘light’ on Quality capability
ERP – QMS - MES
19
QMS
ERP / MRP
» If separate QMS and MES tools used, requires more integration points
» Alternative is to leverage tools that provide both MES and QMS capability
MES
Non-Conformance
MES/QMS
ERP / MRP
ERP – Shop Floor Labor
20
» Shop Floor Labor provides:
» Real-Time Work Order start/stop times
» Support complex shop floor pay rules and schedules
» DCAA time capture compliance
» Accurate Time and Attendance tracking
» Priority only if real-time labor a requirement
Shop Floor Labor
ERP / MRP
TimesheetsOperation Completions
EmployeesWork Centers
Charge NumbersWork Order /
Operations
ERP – Shop Floor Labor - MES
21
» If using an MES, integrate with Shop Floor Labor to leverage operator/technician operation start/stop
Shop Floor Labor
ERP / MRP
TimesheetsTimesheet Approvals
EmployeesWork Centers
Charge Numbers
MES
Work Order / Operations
Operator Sign on/off
ERP – APS
22
APS Capacity Planning & Scheduling
ERP / MRP
Work Order Schedule Updates
Work CentersWork OrdersMRP Rqmts
» Advanced Planning & Scheduling (APS) provides:» Finite capacity planning, Work Order scheduling» Identify bottlenecks» What-If scenario planning» Near/long term resource planning
» Most MRP systems are infinite capacity planning tools» Typically mature manufacturing operations integrated
ERP/MRP to APS solutions» Dependent on accurate Resource Capacity and
Operation Setup/Run times
Benefits of integrating solutions
23
» Removing ‘swivel-chair’ activity
» Improves resource efficiencies
» Improves data accuracy
» Improves data timeliness
Implementing Integrated Solutions
24
» Best practices and tips
» Integrate when business processes and tools are mature (not always feasible)
» Develop an integration roadmap and work towards the fully integrated goal
» Secure handling of sensitive data (ITAR/EAR) in integrations
» Include error handling processes and auditing capability
» Real-Time (or near Real-Time) interfaces keep systems in sync
Implementing Integrated Solutions
25
» Best practices and tips
» Ensure all systems using common Part and Revision identification
» Define only one system of record for each data object, and lock down the other systems if possible
» Leverage Vendor provided integrations/connectors where possible
Implementing Integrated Solutions
26
» Technologies» ETL tools» Flat file imports» Web Services / XML» Database scripts (not recommended)
» File transfer frequency» Scheduled batch files » Real-Time (or near Real-Time)
Deltek’s Project Manufacturing Solution
27
Deltek’s Project Manufacturing Solution
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Costpoint MES
Costpoint Shop Floor
Time
Employee Clockings (Start / Stop)Work Order / Operation Releases
Costpoint
Employee review and sign time cardEmployee Self Service
Labor and time clockings
Employees, MO’s, Accounts, Project, Organizations, Work Centers/Operations, Project Workforce, Inv Abbrev, Parts, MBOM etc.
Routings, Labor reports and completions
Time and Attendance, Approvals, Completions
Touch Points: Costpoint and MES
29
DeltekCostpoint 7.1.1
Deltek CPMES
Employee DataParts
Manufacturing BOMsProject/Acct/Org
Account/OrgWarehouses/Locations
Work CentersOperations
Manufacturing OrdersMO Inventory Issues
Routings/Operationalized BOMsMO Routing Updates
MO Requirement UpdatesManufacturing Order CompletionsManufacturing Order Inspections
Touch Points: Costpoint and Shop Floor Time
30
DeltekCostpoint 7.1.1
Deltek Shop Floor Time
Employee DataEmployee Leave Data
Project/Acct/OrgAccount/Org
PLCProject Workforce
Work CentersManufacturing Orders
Routings
Manufacturing Order CompletionsManufacturing Order Inspections
Time Sheet LinesTime Sheet Approvals
Summary
31
» Compliance is King - leverage ‘Best in Breed’ tools within industry
» Plan out your integrated solution roadmap, and adopt as business processes mature
» Leverage Vendor provided integrations where possible
Questions?
CONFIDENTIAL © Deltek, Inc. All Rights Reserved.32
Paul Whiteman
Partner – Lexell Blue
Ph: 571-214-9613
www.lexellblue.com