A specialised software package enables component suppliers to efficiently integrate with Exostar, the e-procurement system favoured by aerospace and aero-engine manufacturers to keep their global subcontract suppliers informed of delivery requirements.

Exostar-based requirement schedules are normally updated and issued weekly and a new issue can, for most component suppliers, mean manual scanning through hundreds of line items on multiple spreadsheet pages to ascertain the changes from the previous issue. This task, because any error could have serious implications, is usually carried out by a senior manager.

Exo-View is a new package which automatically compares the latest Exostar requirements with existing production schedules to highlight the changes using a very simple traffic light method of identification.

One aerospace contractor user - Kenard Engineering of Dartford - has reduced the task of finding and then determining any repercussions of changes, from a full time senior manager's job performed every week, to a simple two or three hour routine. Each Monday morning Paul Rose, planning manager of Kenard Engineering is faced with an updated Exostar file of between 100 and 150 different parts each with its own spreadsheet. Each part contains information that includes cut-off dates, batch sizes and prices that can be up to five years ahead.

There are often between 2,000 and 3,000 lines of critical information; if changes have been made and are missed or misinterpreted, there can be serious production and delivery problems for Kenard and its customer's customer. Rose has until Friday to confirm that Kenard can comply to the change requests, or to report back any potential problems on quantity, price or delivery date.

Kenard Engineering supplies complex components, often in very expensive materials. It has on its current production file over 100 part numbers, including assemblies for blue-chip aerospace customers, and must conform to the Exostar web-based global procurement scheduling system.

While many view Exostar as an ideal strategy to enable suppliers to forward plan, Kenard found that servicing the system was becoming a full time managerial task, especially with a growing order book. The e-procurement system demanded far greater attention than just number updating as it was subjected to continuous variation to meet customer build and spares scheduling requirements. Some parts carry a manufacturing cost of up to £6,500, and delivery of titanium forgings for instance was going out from 6 weeks to 12 months.

Kenard was already using Seiki Systems' iMES graphical scheduling software and Networked Manufacturing Systems, and called in the software supplier to devise a solution. Within three months Seiki Systems developed Exo-View, a bespoke package that is directly integrated with the Real Time Scheduler, making it possible to automatically analyse the customer's requirements quickly and highlight any changes.

As an immediate result, from requiring the dedication of a full-time Kenard senior manager, the system can now accurately complete the scheduling monitoring task in just 15 minutes. And, within three to four hours, planning manager Paul Rose can have production requirements fully checked out with items needing attention depicted by the simple colour coded traffic light system with red drawing instant attention, yellow warning of a change and green as no change.

In addition to meeting the requirements of Exostar, because Seiki Systems integrated the solution to the current live production data held in the Seiki Systems' Real Time Scheduler, Rose can now view live information giving the exact position and status on work-in-progress, material, CNC machining programs, machine loading and tooling. But what is more important is that he has instant information of any shortfall by being able to obtain an immediate forecast of any possibility of late delivery and see at a glance, the effects on longer term production of other components in the system. It could mean the order amendment requires a batch to be split or batches combined, whether delivery is brought forward or if it has to be delayed.

On a single screen, Paul Rose now knows precise details of material order dates or material received from the supplier, as well as information on the exact operational status such as if production has already started. He also obtains an immediate view of the overall shop loading and subcontract position ready for management decisions to be made.

Says Kenard's Keith Ellis: ‘The problem for a supplier is that Exostar is orientated to the customer; the system has grown from being a document to transfer purchase orders to one that includes planning schedules and inventory positioning.’ Exostar contains, in spreadsheet format, details of part number, purchase order number, delivery date, quantity, unit price and the contracted date required. This final point is a critical element from which the supplier is measured and rated alongside quality performance.

For Kenard, the basic problem was that Exostar was just a spreadsheet listing containing masses of data and any changes were not highlighted by the customer. For instance, quantities could change, and this is critical when such high material costs and long material deliveries were involved. If this were overlooked, the result would be late delivery of the finished part or excessive stock holding of expensive forgings, and the roll-on affect to cash flow.

In addition, the customer could change delivery to different locations, depicted simply by a code, and the unit price - which is often linked to minimum order quantities - could change. For example, if smaller quantities were required, the roll-on effect could seriously affect the time spent setting machines, work in progress, and other orders could be delayed. Also, specialist subcontract processes that Kenard are responsible for could make the order uneconomic.

With the Seiki Systems solution, Exostar data is loaded into a folder within Exo-View which realigns the current batches and delivery through a specially written filter. When an assembly is involved, each part is automatically broken out of Exostar's spreadsheet assembly number and built into the programme.

The viewing screen is then split into two providing an easy to see display using traffic light flagging of changes showing, on one side, Exostar's requirements of order number, part number, date, delivery point, quantity and delivery date, and on the other the respective Kenard scheduling. This enables immediate confirmation of quantities on the original order and comparison of the projected Kenard delivery date against the customer requirement.

By copy and paste, details such as last order date for material, tooling, subcontract and in-production information is automatically linked to total operations completed. The system then re-aligns current batch schedules and immediately feeds back notification of any areas the management team should be aware of. Once the management team at Kenard accept the change, they can respond with any revision requirements or confirmation of acceptance which is then fed back to the customer.

www.seikisystems.co.uk