Original Date: 02/19/2007
Revision Date: / /
Best Practice : Rapid Response (webplan)
In an effort to overcome limitations imposed by an aging operating system, the Raytheon Network Centric Systems Operations Systems team in the company’s Largo, Florida, facility developed a software solution to allow operating data to be extracted into various formats for use by functional organizations. Improved accessibility to data has eliminated the time spent searching through multiple screens, while increased accuracy in material tracking and added simulation capability have allowed more accurate responses to customer requests.
Prior to 2001, Raytheon’s Network Centric Systems (NCS) Manufacturing Center in Largo, Florida, was operating in an environment where extracting data from an aged Manufacturing Resource Planning (MRP) system was constrained by limitations of the system itself. With fragmented data obtainable only by accessing multiple screens and data extract tools requiring expensive and time-consuming programming, Largo was unable to gather meaningful reports needed to accurately monitor and/or trend operational performance. Process stakeholders could not easily obtain shortage information, visibly link supply to demand, or simulate capabilities based on part information.
This scenario changed in May 2001 when the company launched Rapid Response (webplan), a new capability to provide detailed reporting of operating system data in customized formats as designated by individual users or functional groups. Data are pulled directly from MRP into webplan and presented in customized Excel-based formats determined by the user. For example, the “Line-of-Balance Report” (Figure 2-5) serves as a visual indicator of manufacturing status in relation to MRP schedules, with color coding to highlight areas that require attention; the “Cycle Count” form is used to generate random lists for government inventory accuracy audits based on auditor input; the “Purge Process” form is used to identify the location of all units of a particular part number within the factory or on a purchase order in case of emergent problems, which includes units in inventory, on open work orders, installed in next-higher assemblies, and on open purchase orders; and the “Raytheon Enterprise Material Sourcing” report is used to provide visibility of material needs to the corporate level to support companywide purchasing agreements.
The Rapid Response (webplan) capability now provides critical information needed across the Raytheon NCS operation to be available at a glance. Inventory valuation by program and location is immediate; shortage information is readily available and specific to work order; purchase orders and work orders can be visibly linked to independent demand; and Production Control and Procurement personnel can now collaborate online. Forecasting of capabilities is also more accurate since “what-if” scenarios can now be simulated based on part lead-time information to determine critical path.
Figure 2-5. Line-of-Balance Report
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