To: Rick Bullotta who wrote (16905 ) 5/14/1998 12:52:00 PM From: Steve Sanchez Read Replies (1) | Respond to of 31646
one of mr. bullotta's points: 1. TAVA's skill sets are misaligned with those required for this type of consulting. Most of the Y2K assessors are low-level "technicians" and even their senior staff are most comfortable with plant floor controls and automation, not enterprise-wide logistics, including the new hires. one of TAVA's case studies to refute your claim: (from tavatech.com under Case Studies link)Chesebrough Pond's USA Challenge Chesebrough Pond's USA manufactures a variety of consumer products including toothpastes, lotions, creams, hair sprays, deodorants and antiperspirants. "Where we once had one brand of hand lotion, we now have to manufacture a number of different kinds to meet the varying needs of our customers," J. Keith Unger ,manager of automation engineering, points out. Compounding the situation is the intensifying competition from around the world, unpredictable economic conditions and the increasing regulation of products and work floor practices. To be successful, Chesebrough realized they must both improve flexibility and institute more aggressive control of their entire supply chains. Manufacturing needed to be positioned as a strategic opportunity. The construction of a 51,000-sq. ft. expansion in Jefferson City, Missouri offered the opportunity to employ emerging new technologies. All production of Mentadent, Close-Up, Aim and Pepsodent toothpastes are consolidated at this plant. Their challenge was to be able to move products to market faster and be prepared for more frequent changeovers and smaller batches on the production floor. In addition, they had to beat competition - Mentadent's early success was threatened soon after its debut when tartar control versions of arch-rivals Colgate and Crest began to appear. Solution To the rescue: advanced manufacturing technology and a state-of-the-art plant. TAVA Technologies/ACS designed the Jefferson City plant with a new manufacturing system that has an entire batch life cycle that is planned, executed and recorded in one integrated system. John Schaefer, manager of manufacturing systems design at TAVA/ACS, explains that the design effort began with the generation of General Design PracticesT that would govern development of all user interfaces and the control logic. "This would allow the interfaces supplied by multiple vendors and applications to conform to one 'look and feel,' and would simplify system maintenance for plant personnel." Of importance to Unger was the reduction of time it took to begin production of a new recipe . . . from months to hours. So the facility was designed using the Instrument Society of America's new SP-88 guidelines for the design of batch processing controls. "The reason I am such a believer in the new SP-88 guidelines," Unger says, "is because of the flexibility they give us to create and reuse recipe procedural libraries." The sophisticated control system was designed to integrate and aggressively manage all steps in the operation, including production scheduling, inventory supply and control, process control and automation, quality control and engineering maintenance. To operate this sophisticated new facility, TAVA/ACS created one of the first fully-integrated SCADA/MES applications. The system integrates supervisory control and data acquisition with high-level batch management, all supported by an open-architecture, relational database management system running on a Hewlett Packard server. Outcome The facility received the Automated Plant of the Year award from Control Magazine, a leading industry publication. More important, Chesebrough protected its early Mentadent advantage from competitor attack by racking up a 2.6% increase in oral-care market share from 1993 to 1994. The construction schedule was beaten by three months, which Chesebrough attributes to TAVA/ACS' formalized design methodology. The new control system gives Chesebrough the capability of testing new product formulas right on the production line. This has reduced the time it takes to begin production of a new recipe . . . from months to hours. The new facility is seeing benefits in inventory tracking, on-line recipe optimization, increased throughput and quality control. (end of case study) there are other case studies given. steve