implementation of a paperless environment to support a manufacturing shop floor

1. PPaappeerrlleessss SShhoopp FFlloooorr

2. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
1. We are not sure the last router instructional
change was received OR the obsolete
instruction was removed ?

3. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
2. We have many versions of hard copy CAD
drawings FOR THE SAME PART.. Removal of
obsolete versions not guaranteed.

4. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
3. We have problems with printed forms and
handwritten input:
Data errors – no enforceable edits
Illegible handwriting
Untimely collection / reporting

5. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
4. Our routings, CAD drawings, and quality
f o r m s a r e ‘ b o r n d i g i t a l ’ bbuutt tthheeyy aarree pprriinntteedd
ffoorr sshhoopp fflloooorr uussee

6. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
5. We want video based work instructions but
don’t know how to start

7. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
6. Our employees rely on handwritten notes
on printed instructions

8. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
7. Our shop floor transactions are complex
a n d t i m e c o n s u m i n g .

9. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
7. Our shop floor transactions are complex
and time consuming.
We need bar code
technology to simplify, save time and
eliminate errors.

10. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
8. Training our new employees is ongoing,
requiring mentoring from more
experienced
employees
We
need to
improve
training
methods

11. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
9. We are not confident obsolete
documentation was removed from all filing
cabinets

12. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
1100.. Our business requires signature approvals.
Can electronic documents comply ?
PPPPllllaaaannnntttt WWWWoooorrrrkkkk IIIInnnnssssttttrrrruuuuccccttttiiiioooonnnn

13. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
1111.. Our instructions aren’t updated frequently
because of the cost and time involved
Printers – ink cartridges - paper

14. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
1111.. Our instructions aren’t updated frequently
because of the cost and time involved
Cabinets (storage space / cost)

15. IIss TThhiiss YYoouurr SShhoopp FFlloooorr ??
1111.. Our instructions aren’t updated frequently
because of the cost and time involved
Replace old instructions with updates

16. CCoonnvveerrssiioonn TToo PPaappeerrlleessss
Step-by-Step:
1. 1111....
Purchase Adobe Acrobat software. Convert
documents (work instructions, CAD drawings)
to PDF.
PPoorrttaabbllee DDooccuummeenntt FFoorrmmaatt
Developed in 1993 by
Adobe Systems

17. PPPPDDDDFFFF::::
CCoonnvveerrssiioonn TToo PPaappeerrlleessss
Captures text, fonts, graphics
from a variety of software
Documents can be sent
to any PC or printer
Is independent of
application software,
hardware, or operating
system.

18. CCoonnvveerrssiioonn TToo PPaappeerrlleessss
DDooccuummeenntt
CCoonnvveerrssiioonn
MSOffice (Word, Excel)
Any software with a
‘Print’ function can be
converted to PDF

19. Step-by-Step:
2. 2222....
Purchase / install hardware (PCs, monitors,
bar code scanners) on shop floor
CCoonnvveerrssiioonn TToo PPaappeerrlleessss

20. CCoonnvveerrssiioonn TToo PPaappeerrlleessss
Step-by-Step:
3333....
3. Create training material – train SF employees

21. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
1. PDF is the industry standard for viewing
documents on . . .
Smart
phones
Tablets
Desktops
Laptops

22. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
2. Adobe PDF Reader is FREE
ANY computer can view PDF files

23. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
3. PDF reduces file size – files open quickly
Example:
Work instruction
4. Adobe PDF Reader supports document security:
Prohibits altering
documents
Can be setup to
prevent printing
354 KB 120 KB

24. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
5. PDF solution can be independent of, or
support ERP software (Oracle, JD Edwards,
SAP)
6. PDF has easy-to-learn navigation / viewing tools
Page Navigation
First-Prev-Next-Last Page
Zooming / Magnifying

25. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
PDF supports bookmarks Bookmarks go directly to desired
page (Ex: router op sequences)

26. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
PDF supports bookmarks and links to view
other files
PPllaanntt WWoorrkk IInnssttrruuccttiioonn
559999--8888--0022 RReevv BB
CClliicckkiinngg hhyyppeerrlliinnkk ooppeennss ddooccuummeenntt

27. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
PDF supports bookmarks and links to view
other files
CCAADD ddrraawwiinngg ((22DD oorr 33DD)) iiss ddiissppllaayyeedd

28. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
PDF ‘zooming’ tools are excellent
WWeeaarr aapppprroovveedd gglloovveess wwhheenn hhaannddlliinngg tthhee ppaarrtt..
Using the zoom icon,
draw a box around
the area to be
magnified

29. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
PDF ‘zooming’ tools are excellent

30. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
9. PDF supports digital
signatures with
password control
PPPPllllaaaannnntttt WWWWoooorrrrkkkk IIIInnnnssssttttrrrruuuuccccttttiiiioooonnnn

31. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
9. PDF supports digital signatures
Signature location defined by drawing a box on
document
Format of signature
block defined by
approver
Signature history
resides with document

32. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
10. PDF supports document keyword searching
Example: Find all
instructions for
‘6504.31’

33. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
10. PDF supports document keyword searching

34. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
11. PDF supports electronic forms
Design – Distributing - Data Collection - Reporting
DDeessiiggnn ffoorrmm ttoo iinncclluuddee::
Calculations
DDaattee sseelleeccttiioonn ffrroomm ccaalleennddaarr
LLiisstt ooff vvaalluueess
CChheecckk bbooxxeess
RRaaddiioo bbuuttttoonnss
DDiiggiittaall ssiiggnnaattuurreess
DDeecciimmaall pprreecciissiioonn
MMaannddaattoorryy // ooppttiioonnaall
AAdddd bbaarrccooddeess
SSppeellllcchheecckkiinngg

35. 1111 RReeaassoonnss FFoorr UUssiinngg PPDDFF
11. PDF supports electronic forms
Design – Distributing - Data Collection - Reporting
EEddiittss EEE
EEE EEE
EEE EEE EEE
EEE EEE

36. PPrreesseennttaattiioonn OOppttiioonnss
If minimal job instructions – create a table with
hyperlinks
Clicking
hyperlink
displays the
proper
job instruction

37. PPrreesseennttaattiioonn OOppttiioonnss
If many job instructions – add barcode to job router
AACCEE MMAANNUUFFAACCTTUURRIINNGG
Clicking
bar code
displays the
proper
job instruction

38. IImmpplleemmeennttaattiioonn CCoossttss
Required
Network document storage with acceptable
employee access

39. IImmpplleemmeennttaattiioonn CCoossttss
Software Costs
Viewing documents
Acrobat PDF Reader
Free
Creating documents
Adobe Acrobat Purchase
1 license per creator
New license
Upgrade
AAAAccccrrrroooobbbbaaaatttt 11111111
$$
$$
$$
$$

40. IImmpplleemmeennttaattiioonn CCoossttss
Software Costs
Adobe Acrobat Professional only
Subscription plans
1 license for 2 PCs
AAAAnnnnnnnnuuuuaaaallll PPPPllllaaaannnn
$$1199..9955 // mmoo
BBiilllleedd AAnnnnuuaallllyy $$226600
MMMMoooonnnntttthhhhllllyyyy PPPPllllaaaannnn
$$2255 // mmoo
$$330000 // yyrr
AAddvvaannttaaggee::
FFrreeee UUppggrraaddee ttoo NNeeww RReelleeaasseess

41. AAccrroobbaatt SSttaannddaarrdd vvss.. PPrrooffeessssiioonnaall
PPrrooffeessssiioonnaall vveerrssiioonn iinncclluuddeess ffuunnccttiioonnaalliittyy ttoo::
1.Assemble many file types into polished, organized
PDF ‘Portfolio’. Includes layouts and visual themes.
2.Permit Acrobat Reader users to:
Participate in shared reviews with
commenting / markup tools

42. AAccrroobbaatt SSttaannddaarrdd vvss.. PPrrooffeessssiioonnaall
PPrrooffeessssiioonnaall vveerrssiioonn iinncclluuddee ffuunnccttiioonnaalliittyy ttoo::
1.Assemble many file types into polished, organized
PDF ‘Portfolio’. Includes layouts and visual themes.
2.Permit Acrobat Reader users to:
Participate in shared reviews with
commenting / markup tools
Digitally sign PDF documents / forms

43. AArree EElleeccttrroonniicc FFoorrmmss iinn SSccooppee ??
Software Costs
Adobe LiveCycle Designer
$299 per license

44. IImmpplleemmeennttaattiioonn CCoossttss
HHaarrddwwaarree UUnniitt CCoossttss
Desktop PC
Touch screen monitor
$ 300 $ 350 23” screen
Requires Windows 7 or later
RRRReeeevvvviiiieeeewwww

45. IImmpplleemmeennttaattiioonn CCoossttss
HHaarrddwwaarree UUnniitt CCoossttss
Touch screen monitor
Solution Pros:
1) Portability
2) Don’t have to buy 1 for 1 RRRReeeevvvviiiieeeewwww
$ 350 23” screen
Laptop
$ 300 - 350
Requires Windows 7 or later

46. IImmpplleemmeennttaattiioonn CCoossttss
HHaarrddwwaarree UUnniitt CCoossttss
Bar Code Scanner
Wireless $ 375
Wired $ 114

47. IImmpplleemmeennttaattiioonn CCoossttss
PPoossssiibbllee EEnnvviirroonnmmeennttaall CCoossttss
PC enclosures

48. IImmpplleemmeennttaattiioonn CCoossttss
PPoossssiibbllee EEnnvviirroonnmmeennttaall CCoossttss
Monitor / laptop covers
Wireless evaluation
Determines wireless equipment needs
based on coverage area and equipment
interference issues

49. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss
Current versions
of SF documents
always available

50. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss
Eliminates time / cost spent printing, distributing, filing and retaining paper

51. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss
Bar coding facilitates faster data collection, lower costs and reduced human keying errors

52. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss
Easy-to-access video opens up
a new SF instructional media
Engineering time and costs
reduced for version control
and document signoff

53. PPaappeerrlleessss SShhoopp FFlloooorr BBeenneeffiittss
Improve employee training by having all SF
information available online

54. SSuummmmaarryy
RReeaassoonnss TToo CCoonnvveerrtt NNooww
Hardware is proven. Many low cost options exist.
Wireless technology is proven. No need to ‘hard wire’ PCs. Easy SF physical reorganization.

55. SSuummmmaarryy
RReeaassoonnss TToo CCoonnvveerrtt NNooww
PDF is the:
Industry standard for
viewing documents
Low cost alternative to
document management
software

56. SSuummmmaarryy
Hardware, software and wireless technology is proven and works well together

57. SSuummmmaarryy
Key to a successful project:
Fostering and managing organizational change

58. MMoovvee TToo 2211sstt CCeennttuurryy MMaannuuffaaccttuurriinngg
Scrap Paper

59. MMoovvee TToo 2211sstt CCeennttuurryy MMaannuuffaaccttuurriinngg
Scrap Paper
Go
Paperless

60. MMoovvee TToo 2211sstt CCeennttuurryy MMaannuuffaaccttuurriinngg
Scrap Paper
Go
Paperless
Years of Experience:
36 - Information Systems
17 - ERP (Mfg / Distribution / Bar Code)
11 - Business Intelligence Reporting

61. PPaappeerrlleessss SShhoopp FFlloooorr
DDeemmoo