In manufacturing environments it is often cumbersome to manage the processing of work orders in JD Edwards. Manual paper-based recording of activities is required, followed by bulk data entry in the ERP system. This is prone to error and requires significant administrative overhead. In this case a complex manufacturing process, involving steel slitting operations, required heavy customisations in JDE. Even with these customisation in place, Orrcon would have experienced inaccuracies,bottlenecks and excess overhead. As an alternative, RFgen was used to automate this shop floor process and to combine these into a single transaction run on a terminal at the end of each production line at Orrcon's Salisbury plant. This process included multiple transctions and custom business logic.Barcode scanning was used to provide the necessary accuracy needed for the process to be real time. This simplification gave the business immediate benefit while keeping business-specific customisations outside of JDE, de-coupling the environment.

1. Automated Shop Floor Management using RFgenDarren Swindells & Craig WestcottHills Industries & Fusion5Monday 16th August 2010 The most comprehensive Oracle applications & technology content under one roof

2. Agenda Background Business Problem Solution Criteria & Alternatives Solution Overview Project Outline Business Benefits Questions

3. Background Orrcon Steel (part of Hills Industries) is an Australian manufacturer and distributor of Steel, Tube and Pipe Specialises in the manufacture of precision tube, structural pipe, water pipe, and oil gas pipeline Used in large construction projects One of the leading players in the Australian market, with a strong local distribution network Core to the business is the steel slitting & rolling mills Based in Queensland (live site) and In South Australia (future site)

4. Steel Slitting at Orrcon Steel coil slitting operations at Orrcon plants Batches of steel coil received by rail or road Output coils rolled and stored/ used in steel tubing

5. Agenda Background Business Problem Solution Criteria & Alternatives Solution Overview Project Outline Business Benefits Questions

7. One galvanised in-line slitter & one hot-roll slitting line

8. Slitting machines running on each line

9. Input coils fed into process, in batches

10. Slitters generate multiple output coils/WO’s

11. Which are rolled and packed for storage/use

13. Multiple output coil/WO completions

14. In a single operation for the full batch

15. Real-time, with reference & lot # validations

16. Handling tolerances, scrap & other calculations

19. Scans reference & lot #’s (coil)

20. Enters various input parameters

21. Performs completions/issues

22. Consumed in Weight or Metres

23. Completed in Metres

24. Fully consumes master coil across patternSuperbackflush WO completions for all output coils in the batch, and Validations, calculations & WO issues to take place in JDE, in real-time

26. Need to automate & simplify process

27. Scanning required for accuracy

28. Possible bottlenecks – manual steps

29. Delayed ERP steps – affects visibility

30. Performance & practicality concerns

31. Running ERP session on production line

32. Screen format, button size, etc issues

33. Risk of high admin costs

35. Data captured automatically

36. ERP updated in real time

37. Scanning built in – accurate validation

38. All in 1 process – no manual ERP steps

40. No admin overhead – real time in ERP

41. Aligned with Hill’s SOA standardisation- ERP vanilla- custom code external

42. Agenda Background Business Problem Solution Criteria & Alternatives Solution Overview Project Outline Business Benefits Questions

43. Solution Overview RFgen (www.rfgen.com) Automated Data Capture solution was chosen Provided by Fusion5’s Supply Chain division (www.fusion5.com.au) Fully integrated with JD Edwards – real-time ERP updates Software runs on terminals at the end of each line Users transact through simple touch screen forms Barcode scanning built in for real-time batch & lot # validations Additional custom logic & validations built into transactions Automatically prints barcode labels off after transacting (re-print too) Handles multiple ERP WO completions & issues for batch in a single step from the transaction (simplification)

44. Solution Overview

45. Agenda Background Business Problem Solution Criteria & Alternatives Solution Overview Project Outline Business Benefits Questions

46. Project Overview RFgen’s development platform used for custom functionality Fusion5 team working with Hills to: Specify & document requirement Scope out solution, and deliver technical documentation Develop new functionality using RFgen platform Unit & integration test solution into JDE Cutover & go live with new solution Involved the following key resources: Hills: business analyst & Orrcon staff members Fusion5: PM, architect, analyst & RFgen/JDE developer

47. Project Outline

48. Agenda Background Business Problem Solution Criteria & Alternatives Solution Overview Project Outline Business Benefits Questions

49. Business Benefits Improve accuracy Real-time visibility Remove process bottlenecks Improve efficiencies Reduce administration costs Automation - consolidation & simplification SOA standardisation – de-coupling Improve customer service

50. Some Immediate Outcomes Usability Significant usability benefits: error reduction & simplicity in usage User training Training time reduced six-fold – now takes only 15% of the time Removing ERP customisation Custom business logic removed from ERP Eg Warnings if only 90% of the coil is issued Applies automated rules that are derived outside of std JDE business functions JDE upgrade benefits Removal of customisations speeds up JDE upgrade process significantly

51. Agenda Background Business Problem Solution Criteria & Alternatives Solution Overview Project Outline Business Benefits Questions

52. Questions Thank You! Q&A

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