1. =

2. Overview
Premise:
– A fully integrated, real-time automated data collection
solution:
• Is essential for multi-site implementations
• Yields a very high benefit level
Evidence:
– GKN Driveline and Eagle Consulting and
Development will use GKN’s US implementation to
demonstrate their strategic approach to multi-site
implementation and how that approach yielded
specific benefits

3. High-Level Goals and Benefits
GKN wished to:
– Build a sophisticated, inter-related network of sites
that could transfer materials and components 24
hours a day
– Track each transfer, in real time, as the sites “feed”
one another
– Use offsite warehouse facilities to monitor the
movement of material into the manufacturing sites
– Meet the stringent requirements of Honda and other
high-profile automakers, including Just-In-Time
product delivery.

4. The Multi-Site / Multinational Rollout
Unique challenges and requirements
– Maintain seamless connection between sites
– Transfer materials between sites efficiently
– Establish and maintain high levels of visibility
into the network of sites
– Address differences in local equipment, process
and people
– Meet varying end-customer requirements

5. About GKN
Company background
– World’s leading producer of automotive driveline
components
– A global tier-one supplier
– 21,000 people at 49 locations in 31 countries.
Power Transfer Unit
GKN Driveline's PTUs are compact,
lightweight, have excellent NVH (noise,
vibration, harshness) characteristics.
This makes them a popular choice in a
large range of applications.
Copyright GKN plc

6. About GKN
An industry leader
– Closely involved with many key milestones in
automotive history. A recent example:
• Jan 2006 announcement: Vehicle makers plan to introduce
breakthrough technology from GKN Driveline that
provides lighter driveshaft components, improved fuel
economy and better overall vehicle performance… including
reduction in driveline noise, vibration and harshness.
• This has been described as the first major change
in constant-velocity-joint (CVJ) technology in
more than 70 years
• GKN Driveline currently produces more than
95 million CVJs per year

7. GKN’s Requirements
 External
– Meet automaker requirements (e.g., Honda)
– Meet end customer requirements
• GM, Ford, Honda and others
 Internal
– Replace existing automated data collection system
and see significant improvements
– Increase the number of transactions
captured in real time
– Reduce the number of disconnected systems

8. GKN’s Expected Gains
 Achieve savings
– Eliminate waste
 Increase productivity
– Gain access to more
accurate reporting
 Improve accuracy
– Reduce human intervention
– Establish consistent process
across sites Copyright GKN plc
 Leverage QAD MFG/PRO capabilities

9. Why choose
Eagle’s solution:
RF Express™ for
MFG/PRO

10. Technical considerations
RF Express for MFG/PRO:
– Provides a seamless, plug-and-play integration
with QAD MFG/PRO
– Is an online, real-time, PROGRESS-based
automated data collection and bar coding solution
– Enables all Eagle customers to enjoy the benefits
of simplified data entry, portable terminals,
barcode scanning/labeling, as well as integrated
scale weight transactions and the ability to
print portable bar code labels
– Makes it possible to configure functionality
on a site-specific basis

11. Technical considerations (continued)
RF Express for MFG/PRO:
– Does not require any side databases or separate
server platform
• multi-site implementations do not require
a separate server for each physical site
– Operates in Linux, Windows and UNIX environments
– Supports both Progress and Oracle databases
– Calls QAD MFG/PRO edit and update routines
to provide real-time data checking with
enhanced functionality

12. Technical considerations (continued)
RF Express for MFG/PRO:
– Supports a wide array of devices,
including:
• RF handheld networks
– IEEE 802.11BG Direct Sequence
– Fixed shop floor stations with laser
scanners
• RFID tags
• Fixed RF printers
• Portable RF printers Copyright GKN plc
• Scales
• Thermal transfer printers
• Bumpy bar codes

13. Cost considerations
Less hardware and software are required
because RF Express for MFG/PRO uses the
existing database and existing server
Reduced database/server ongoing maintenance
Simplified database control: QAD MFG/PRO
and RF Express for MFG/PRO work together

14. Industry Acceptance and Usage
 Eagle has provided solutions to the QAD MFG/PRO
community since 1992
 Eagle’s solution is currently installed at 800 customers
and over 3,000 sites worldwide
 Eagle is used only by QAD MFG/PRO customers, so all
installations are also QAD MFG/PRO installations
 Eagle’s customer list includes Fortune 500 companies
worldwide in every industry served by QAD
 Eagle’s status as a Honda-approved solution provider,
as well as its experience with FDA compliance issues,
enables Eagle to add value in addressing industry-
specific requirements

15. Customer Satisfaction
Eagle consistently achieves Excellent
customer ratings not only on its product, but on
its responsiveness, support and service
For specific customer comments, visit Eagle’s
booth for a copy of What Our Customers
Say

16. Key Process Points
–
RF Express for
MFG/PRO

17. Scope and Project Plan
 Initial onsite analysis July 2004
– Primary implementation site identified
– Site-specific requirements identified
– Initial software pilot environment setup completed
 Training/piloting activities Sept 2004-Feb 2005
per GKN timeline
– Honda EDI/label testing
– Test 50+ other ship-scenarios
– GKN brought key representatives from each site
to the “training house”

18. Timelines: GKN’s and Eagle’s
Go Live February 2005---All sites
– Key support from the primary site

19. Implementation
Nuts and Bolts
RF Express for
MFG/PRO

20. Eagle User Requirements
Keep the transactions simple
Maintain Pallet/Container Reference number
Capture transactions in real time

21. Eagle Transactions
Inventory Management Module
Advanced Repetitive
Enhanced Shipping
Warehouse Management

22. Inventory Management Module
PO Receipt
Pallet Move
Component scrap

23. Advanced Repetitive Module
Kanban Backflush with Container Label Create
Backflush with Multiple Container Label Create

24. Enhanced Shipping Module
Load Truck
– With automatic additional container item add
Verify Load

25. Warehouse Management Module
Pallet Distribution Order Ship
Pallet Distribution Order Receipt

26. Eagle Transactions Linking the Sites
Alamance Site
produces a component to be
Roxboro Site
used in Roxboro using backflush
places an intersite request via
transaction
QAD MFG/PRO
fulfills the request using the receives the product via Pallet
Pallet Distribution Order Ship Distribution Order Receipt
transaction transaction
moves the components to the
work center location via Pallet
Move/Unlink

27. Hardware
Maintain existing Intermec Trakker Antares
handheld terminals & RF backbone
Maintain existing Intermec printers
Maintain “rolling” portable Intermec printers

28. Implementation and Synergy
Effective use of pilot scenarios
– Pilot scenarios represented real-world activities
– Users caught on very quickly
– Users were able to articulate
the site-specific requirements
– GKN used RF Express for MFG/PRO extensively
to deliver training between Eagle visits
Multiple pilots lead to a smooth go-live

29. Usage Between Plants
Introduced in transaction section
– Distribution orders
Critical to GKN business
– Uses Kanban system to drive interplant requisitions
– Requisitions are fulfilled using Pallet Distribution
Order Ship Transaction
– Product is received 24 hours/day using Pallet
Distribution Order Receipt Transaction
Provides best input to MRP

30. Lessons Learned
Multi-site simultaneous go-live was
critical to success
Training must be thorough at all sites
System stress test was very important
Around-the-clock support quickly addressed
issues
– System experts were available to the users

31. Global Rollout
Previous sites
– Asia
This implementation
– North America
Future (now!)
– Europe
– South America

32. Contact Information
John Malvaso Jim Miceli
IS/IT Manager for Business Applications Senior Project Manager
GKN Driveline North America (DNA). Eagle Consulting and Development
6400 Durham Road 135 Kinnelon Road, Suite 204
Timberlake, NC 27583 USA Kinnelon, NJ 07405
+1.336.364.6449 +1.973.838.5006
+1.248.364.7681 (fax) +1.973.492.2758 (fax)
John.Malvaso@gkndriveline.com JMiceli@EagleConDev.com
www.gkndriveline.com www.eaglecondev.com
RF Express™ for MFG/PRO is a trademark of Eagle Consulting and Development.
“QAD” is a registered trademark of QAD Inc.
All other products or Company names herein
may be trademarks of their respective owners.