Conference Program

Tuesday, September 14, 2004
9:00 a.m. - 10:00 a.m.	KEYNOTE PRESENTATION: "Why Manufacturing Matters" Bruce Richardson, Senior Vice President, Research, AMR Research (READ BIO) Can you name a single company with a Chief Manufacturing Officer? This will change over the next five years as new CMOs assume corporate responsibility for quality, product cost, on-time delivery, customer satisfaction, and meeting revenue targets and profitability. This presentation takes a look back at the progress made in manufacturing since the introduction of MES in 1991, and anticipates some of the key trends to emerge from 2005-2010.

MANUFACTURING EXCELLENCE AWARDS - FINALIST PRESENTATIONS
Manufacturing Excellence - Product Quality
10:45 a.m. - 11:15 a.m.	MES and Quality: A Product and Profit Recipe for Supply Chain Success Walt Staehle, Kraft Foods, Inc. (READ BIO) Kraft Foods has taken an integrated approach to improving and protecting Product Quality; investing in MES principles to guide a multi-year $ capital outlay to provide the tools to capture, analyze, share and act on plant quality information in real-time. The 3- year investment is now in place at 54 plant laboratories, impacts 700+ production lines and influences over a dozen multi-million $ product categories in the Kraft Foods network. The return of over $22 million in on-going savings is being generated by a 50% reduction in rework levels, a 30% reduction in process variation, a 10% improvement in product yield and a Laboratory labor reduction of 30 FTE’s.
11:15 a.m. - 11:45 a.m.	When Quality Meets Technology Everyone Benefits Kreg Kukor, Cequent (READ BIO) In July 2002 Cequent Electrical Products formerly Tekonsha Towing systems primarily an Aftermarket provider of Electric Trailer Brake control systems, began their assessment and implementation of a Quality system compliant to QS-9000. Opportunities to break into the Tier 1 and OEM automotive environment with a Major Big Three Automaker were at the forefront of our Business plan, the RFQ arrived and so did the work. In less than 9 months Cequent Electrical Products attained QS certification and Implemented a metrics driven quality system utilizing the ASP model offered by IQS Inc based in Cleveland Ohio. The performance results are staggering.
Manufacturing Excellence - Customer Service & Support
11:45 a.m. - 12:15 p.m. Bode Fenters	Granular Graphite MES: A Competitive Advantage David Bode, Showa Denko Carbon, Inc. (READ BIO) Kevin Fenters, Pyramid Software, Inc. (READ BIO) One key attribute of a Manufacturing Execution System is its ability to produce goods that meet stringent, complex customer requirements. The challenge is to utilize this attribute to create a competitive advantage in the marketplace while maintaining the lowest possible production cost. When Showa Denko Carbon identified a higher value-added market for one of its products, it used an MES to successfully meet that challenge. This presentation will provide insight into the full life cycle of the system from concept to implementation. In addition, information will be provided to illustrate how the system has evolved since 1996 to meet a continuously changing market.
1:15 p.m. - 1:45 p.m.	Lenox China Improves Customer Service with a MES Richard Santoriello, Lenox, Inc. (READ BIO) Lenox China, a 100-year plus manufacturing company that values customer loyalty and product quality have a proud legacy of continuous improvement. Market demands drive a need for more accurate control of the order fulfillment process and improved product quality. Lenox looked beyond their existing processes and systems for solutions that could deliver production visibility and improve supply chain accuracy and velocity. Lenox launched and implemented a corporate MES initiative to develop common practices, processes and systems, but the road to implementation was challenging and full of organizational and process issues. Corporate IT wanted to standardize the MES across all facilities in order to minimize the need of a support staff. The Plants’ needed flexibility, visibility and analytical tools in order to improve customer service and did not want a corporate solution that added additional work. The presentation will include how Lenox got its project started, obtained organizational (plant & corporate) consensus and how they have met their objectives to establish a collaborative MES that will help them to maintain a competitive advantage as the firm enters the 21st century.
Manufacturing Excellence - Manufacturing Efficiency
1:45 p.m. - 2:15 p.m.	Hybrid Stack Architecture Randy Randall, Fuji Photo Film (READ BIO) Today, technology "experts" often tout the benefits or the dangers of using open-source solutions versus commercial solutions. But maybe the conversation should not be about which one to use but about where to use each. Using the Hybrid Stack Architecture allows businesses to employ open-source solutions in line with commercial solutions to work with the strengths of both. The Hybrid Stack provides today's manufacturers with the ability to take off-the-shelf solutions, use them as intended, and then supplement them with other solutions to meet the specific business requirements.
2:15 p.m. - 2:45 p.m.	Roll Roundness Verification System Julio Pascual, The Washington Post (READ BIO) The Washington Post receives out of round newsprint paper rolls which cause production problems, web breaks and slower press speeds. On two occasions, a high number of out of round rolls caused multiple press stops and severely disrupted production, forcing the transfer of production to another facility to avoid late newspaper deliveries. Previously, we had no system to verify roll roundness that did not interrupt or delayed production. TWP developed a method to measure roll roundness during the receiving process to insure sufficient acceptable rolls for nightly press runs and eliminate out-of-round rolls from the limited roll storage areas.
3:15 p.m. - 3:45 p.m.	Removing the Complexities in Systems and Process for Global Manufacturing Efficiency Chris Towns, Pemstar, Inc. (READ BIO) Pemstar has taken a strategic approach to building a global manufacturing environment. With facilities that span Europe, U.S., South America and Asia, Pemstar’s business of supplying engineering, manufacturing and fulfillment services to electronics and medical device organizations depends on real-time alerting, unhampered visibility and informative knowledge across operations, process and people. In addition, Pemstar’s manufacturing operations demand the flexibility to support changes anywhere, traceability from supplier to customer, and the ability to report on operational trends or issues. Chris Towns will review his strategy of using best-in-class IT and Manufacturing expertise to create a system that supports Pemstar’s business objectives such as improved time to market, reduced operating costs and reduced risk, while delivering optimized and efficient operations management.
3:45 p.m. - 4:15 p.m.	Hitachi Traceability Implementation Shaun McGinnis, Hitachi Computer Products (READ BIO) Hitachi Computer Products (America), Inc. Norman, OK, produces large-scale data storage systems from PCB to System Build as well as offering professional/engineering contract manufacturing services. The project objective was to implement/develop a Quality & Traceability system (VISIPRISE) and integrate the application with existing systems (PEOPLESOFT, AGILE, EASE) to improve accuracy and timeliness of data. Commitments to quality improvement activities, support growing government and environmental regulations, and meeting customer needs were driving the need for more data to be collected during the manufacturing process. The resulting integration of systems and new processes had to support increased data collection with no increase to recently reduced production lead times.
Wednesday, September 15, 2004
8:45 a.m. - 9:30 a.m.	FEATURED PRESENTATION: "MESA, Manufacturing, the Future and You" Richard Morley, R. Morley, Inc. (READ BIO) Dick Morley will present the year 2010 for MESA. What does 2010 hold for MESA and, more importantly, your career? Will it take the road most often traveled by history? The lessons of software, computers, printing, railroads, canals and sailing ships suggest that we best prepare for stability and the dearth of opportunities. The big boys win and others whither in the coming winter. Dick Morley suggests some alternatives for the organization and the members. Always entertaining and controversial, he suggests at least two cups of coffee before attendance.
10:15 a.m. - 11:00 a.m.	MES as a Competitive Weapon Julie Fraser, Industry Directions (READ BIO) Manufacturing Executives are striving to improve profits and increase productivity. Among the best performing plants in North America, those that use Manufacturing Execution Systems (MES) were able to increase profitability by four times as much as the others. This groundbreaking research by analyst firm Industry Directions shows that some of the most impressive plants in the US use Manufacturing Execution Systems (MES) extensively and achieve dramatic performance gains. This presentation will compare the performance of Industry Week's Best Plants using MES vs. those not using MES and indicate how companies can compete more effectively through MES investments and use.
11:00 a.m. - 12:15 p.m. Gifford Grasley Moore	Discussion Panel: Collaborative Manufacturing - Theory vs. Practice Moderator: Charlie Gifford, GE (READ BIO); Participants: Mike Grasley, Aseco (READ BIO); John Moore, KLA-Tencor (READ BIO); Alison Smith, AMR Research MES has become a critical component of a company’s IT application support for supply chain, product lifecycle management, customer and supplier relationship management. . It provides core data and a platform for cross-functional collaboration and business success. Consequently, MESA has updated its model to reflect the functional and collaborative activities of the current manufacturing environment. A short overview of the Next Generation MESA Collaborative MES or c-MES Model will be followed by a panel discussion on how MES theory and practice differ and on how relevant MES models and standards are to improving practice in industry. The Panel presents the view points of an End user, MES Vendor, Industry Analyst and Systems Integrator/Consulting Firm.
1:15 p.m. - 2:00 p.m.	How to Leverage MES with RTM Roberto Werneck do Carmo, Senior Project Manager, Chemtech (READ BIO) MES applications show their strength in the integration and use of information for decision-making. Today, this technology can be used as a support for more ambitious implementations designed to make decision-making information available. These applications are currently known by different names such as Operations Intelligence (OI). Companies that have used OI already report considerable, measurable gains. A main goal of OI is to bring about a faster decision-making cycle. Solutions that integrate both MES and OI can take advantage of MES to close the loop and implement the decisions quickly, thus turning the potential benefits of OI into solid benefits.
2:00 p.m. - 2:45 p.m.	ISA 95 Implementations and the New Models for Collaborative Production Management Dennis Brandl, BR&L Consulting (READ BIO) The ISA 95 Enterprise/Control System standard is rapidly gaining acceptance in a wide range of industries and has already been used in major implementations. Companies applying the standard in the area of ERP to MES integration have reduced implementation times by over 75%. Other companies are using the new model of Collaborative Production Management, defined in ISA 95 Part 3, as a template for requirement specifications, architecture, design and implementation. The templates have allowed companies to compare CPM solutions, comprised of MES, LIMS, CMM, and WES systems, and to develop integrated shop floor systems. This presentation will list where and how the standard has been applied.
3:15 p.m. - 4:00 p.m Englehard Tetzlaff	Lean and MES: Alignment, Coordination and Integration for High Performance Dan Englehard, Hampton Tilley (READ BIO) August Tetzlaff, BKD (READ BIO) Organizations can realize tremendous productivity gains with initiatives in Lean and MES when those initiatives are effectively lead and managed. A significant challenge exists where the intent is to leverage the combined potential of each. Achieving synergy within and among efforts in Lean and MES pays off. We will discuss ways to achieve alignment, coordination and integration as well as barriers and hazards to work through or avoid. This presentation examines 20 elements of Lean and how developments in one or several key lean elements are often adapted in practices which affect current and planned requirements and configuration of MES systems.
4:00 p.m. - 4:45 p.m.	2004 MES Product Survey Report Jan Snoeij, LogicaCMG (READ BIO) For the fifth time, LogicaCMG conducted a MES Product Survey which rates all leading MES Vendors and their product’s features map against different types of industries, the MESA-11 functionalities, the ANSI/ISA-95 definitions, etc. During this presentation, facts of MES implementations will be presented such as size, costs and number of implementations in different market segments. New elements in this years' survey are the availability of mobile solutions and the configurability of the products with respect to business logics, GUI and reporting. This information is not only valuable to any prospective user of MES, but also to MES vendors with respect to the requirements of their products. Last years’ report is used by a couple hundred companies all over the world, on their way to find the right MES solution. Aspects that appeared to be very important to end users during their selection of a suitable MES product will also be reviewed.