Environmental Data Management An End to End Process 2005 IBM Corporation

Transcription

1 Green Product Data Management Case Study - Taiwan Customer Example 綠色產品資料管理 - 台灣製造業案例介紹 November 2005, IBM BCS Taiwan Environmental Data Management An End to End Process

2 Customer Profile Company Background Established in Taiwan in March Annual Revenue NTD16B Currently 6,371 employees. Optical-Electronic Products: scanner, digital camera, phone camera and LCOS projectors Computer Peripherals: mice/pointing devices, gaming controllers, and broadband products Office Automation Equipment: Multi-Functional Printer Communication Accessories: mobile phone and telephone accessories 2 November 2005

3 Phase I Phase II Phase III Phase IV Project Roadmap Standard New Product Development (NPD) process Manage all project related documents Control all the project milestones and reports Part/BOM/EC/Production document design Migrate all Part/BOM data from ERP(SAP) system & SAP Integration Control all the part related documents and release to remote plant DCC NPD improvement & Project Plan Management (PPM) Part numbering improvement from SAP part number system New requirement for RoHS and JGPSSI integration (Green project) Project Info Mngt. Part/BOM Auto Form Docs Mngt Project Deliverables Product Structure Proj. Plan mngt Numbering EC, SAP Integration A B C D E F Green Project G Form Mngt. NPD Mngt. DCC Control PDM & System Integration E PPM F SAP Int. Green Project A B Phase I C Phase II D Phase III Phase IV Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 Q4 Q1 Q2 Q3 3 November 2005

4 End to End Green Data Management Process Why? Accurate Data Enable suppliers to provide all required data in a consistent format via the Product Content Declaration form. Efficient Method for Collecting Required Data Part of PDM Checkpoint Process for Developing Products, Ensures compliance verification of Products prior to announcement date. Rapid Response Capability for Audits Be able to respond rapidly to audit requests, Prevents downtime should governing bodies or customers request an audit of a product for reportable or Green substances. Reduces potential fines or limits time that fines or stop ships would be in effect until compliance proved. 4 November 2005

5 System Architecture Green and Legacy System 5 November 2005

6 Green System Architecture Green Supplier Portal Compliant Reports Report Generating Tool Green Control Module (BOM Analysis, Regulatory check) Item Master and BOM GCM : Green Control Module Customized Green Autoloader (for MCD and green attributes) Suppliers MCD: Material Composition Document Factory Systems Adapt er ERP Adapt er EAI Import Export PDM Database Part Approval, AVL Hazmat Documents Electronics DB Auto-link Program Upload Download Other Supplier Data portal Supplier Systems Structured Integration File Exchange (Data, Reports) 6 November 2005

7 System Diagram (Information Model) Supplier Supplier GP GP Portal Portal Rule/Regulation Rule/Regulation Database Database Management Management Sub Sub Part Part and and Substance Substance Management Management Green Supplier Portal Green Analyzer Testing Testing Report Report Management Management ERP PDM Vendor Vendor approval approval process process Green Green Procurement Procurement Spec Spec Review Review process process Part Part Number Number Request Request Process Process Component Component approval approval process process Component Component change change process process Survey Survey Form Form Review Review Process Process Testing Testing Report Report Review Review Process Process Warranty Warranty Statement Statement Review Review Process Process 7 November 2005

8 System Diagram (Functional Model - RoHS) 參與客戶規格討論 供應商填回 承諾書 內部規格要求 員工訓練 種子成員訓練 PDM Green 登錄及標示 新人訓練 供應商訓練 供應商協助方案 ERP 相關標示 Supporting System 產品轉換計畫 合格供應商 化學物質調查表 供應商填回 合格供應商認證 評鑑表 供應商管理 Intranet / FTP 訓練資料 & 資訊 指定人員確認符合 指定人員轉填客戶表格 客戶表格 Import Data to PDM XRF/ICP 進料檢驗 無鉛製程管理 / 驗證 ERP 系統自動標示 生產作業管理 Manual Operation Spec & Document Green & Comp Lib. Other 8 November 2005

9 System Diagram (Functional Model - WEEE) WEEE 規格要求 客戶 Recycle 作業要求 產品 Recycle 統計 Registration Center Manual Operation Spec & Document Green & Comp Lib. Other WEEE Rate, disassembly instructions by Product 登錄及標示 (PDM) ERP 相關標示 /Financial/Reverse Logistics 計算 9 November 2005

10 End to End Data Process Section 1: DATA GATHERING, VALIDATION AND UPLOADING PROCESS Section 2: PRODUCT ENVIRONMENTAL PROFILE (PEP) MAIN PROCESS Section 3: PRODUCT SPOT CHECK PROCESS Section 4: INCLUSION OF GREEN IN THE LIFECYCLE CHECKPOINT PROCESS Section 5: ENVIRONMENTAL DATA TRACKING OF NEW PART NUMBERS CREATED IN PDM 10 November 2005

11 DATA GATHERING, VALIDATION AND UPLOADING PROCESS Section 1 11 November 2005

12 Suppliers IBM Business Consulting Services Data Gathering, Validation and Uploading Process Green Data External ODM Internal Procurement Engineer No Validation Accept Yes GCM Autoloader GCM: Green Control Module Green Data PDM GCM Analyzer Green Attribute update 1. Engineering (Procurement, Component or R&D Engineers - depending on Product Classification) releases a new part number into the PDM (Product Data Management System). 2. As part of RFI (Request for Information) / RFQ (Request for Quote) processes etc., Procurement Engineering s the declaration form to the supplier for newly released part numbers. 3. The Supplier fills in the environmental data and s form back to the Procurement Engineer. 4. The Engineering part owner reviews and validates the information. 5. If the data is acceptable, the data loader invokes the web-based Autoloader tool Note: Green data=environmental Data=Part/Substance Declaration Form, Supplier Survey Form, Material Test Report, etc 12 November 2005

13 Data Management and Compliance Reporting Process PDM Approval sheet and part re-link Autoloader Brand Rep/Procurement Compliance Reports Green Attribute update Analyzer GCM Reporter Error Queries Note: Analyzer=GCM Analyzer=Engine software or application to check hazardous and/or regulated substance 1. Once the data is in GCM Analyzer and through Error queries can then be generated to determine where there is missing environmental information. 2. GCM Reporter then combines the Product Bill of Material by part numbers and the Green data information to determine product compliance. 3. A product compliance report is then generated. The report is used in conjunction with the approval sheet process and integrated in engineering change process if necessary. 13 November 2005

14 Suppliers IBM Business Consulting Services End-to-End Green Data Management Process Green Data External Internal Procurement Engineer No Validation Accept Yes GCM Autoloader GCM: Green Control Module Green Data Error Queries GCM Analyzer PDM Green Attribute update Brand Rep/Procurement GCM Reporter Compliance Reports 1. In the process, if the data is acceptable, the data loader invokes the web-based Autoloader tool, where the information is automatically uploaded into the GCM database under the part number; and the original form is also stored in the GCM database server. 14 November 2005

15 PRODUCT ENVIRONMENTAL PROFILE (PEP) MAIN PROCESS Section 2 15 November 2005

16 Step 1 - Develop and Verify Initiate Workflow Administrator in the Green team initiates the PEP by completing Product Profile, i.e. product classification and environmental profile Input Product profile The PEP process will notify the Component Engineer who assign PEP reviewers The PEP is now ready to be completed Assign owner The Comp. Eng. will work with R&D manager and to assign section owners. Section owners assignment is based on expertise and development role for the product. The owners are responsible for completing their respective sections as scheduled. Tasking 16 November 2005

17 By the end of the initial test, section owners need to have to have their respective sections completed.. Step 2 - Develop and Verify System PEP Completion Green Team Lead Product Product Composition Composition The Green Team Lead with input from Green members will have the primary responsibility in completing this section address plastics, Electronics, cables and other key sub-assemblies. Comp. Eng. Mfg. Eng. Analyzer Process PB Free Procur ement Eng. Sensitive Sensitive Materials Materials Process Process Commodity Commodity Outsourcing Outsourcing The Component Engineer with the use of the GCM Analyzer tool will search explore database to verify status compliance with Green, banned substances and other material requirements Process engineers owning Process with new Pbfree will complete this section. If the process is not new to most the information can be auto loaded from the database. Procurement engineers owning outsourcing parts utilizing chemicals will need to complete this section At the end of the Develop and Verify phase and all sections have been initially completed. A status report will be provided to the Product/Project Manager. Design Eng. Green Design Green Design Design engineers will highlight the environmentally significant design features of the product. 17 November 2005

18 Green Team Role and Responsibility Role Project Manager Green Team Lead Responsibility Final approver for the Green process Summary and check all product composition Comp Engineer (Coordinator) Coordinate Engineering group to use GCM to Check detail substance composition for individual parts and semi-product Department Managers Procurement Engineer Mfg. Engineer Design Engineer Approve departmental Green check results Check commodity outsourcing parts and vendor green files and update the status Check Pb-Free reports and mfg. process tuning Adopt and highlight the environmentally significant design features of the product. 18 November 2005

19 When all sections have been verified, the PEP Coordinator will start final approval process. Requesting the reviewers to approve or reject. The PEP coordinator may add reviewers at this time. Step 3 : Finalize and Release System PEP Approval PEP Technical review The PEP reviewers are the technical experts in the area of product environmental requirements. These people have been involved from PEP initiation and now sign-off on the product. All issues should have been resolved before getting to this point. Management Review After all technical reviewers have signed-off, the PEP will go for management approval PEP Coordinator After PM approval, The PEP Coordinator finalizes the PEP and moves it into a controlled public view in GCM and PDM. PM Approval After all sign-offs have been completed a PEP report will be submitted to the Product Manager for their concurrence to the product environmental information in the PEP 19 November 2005

20 Sub Process Change in PDM Review Process Part/BOM/EC/Approval Sheet/Supplier Database 20 November 2005

21 Impact to New/Revise Part approval Process T01:Submit to Review Creator T02:Inside Dept. Review Section Manager GREEN Review Green Team Admin NEW GREEN CHECK STEP N01: Notification System T01:Submit to Review T02:Inside Dept. Review T03:MC Review N01: Notification Creator Section Manager MC System In Work Under Review Item Transfer to ERP Active Rework Inactive 21 November 2005

22 Is the part new or is it a current part that has had a material change? New Green Part Checking Process Change If the part has been in compliance with the Green directive in the past 90 days? NO Yes Ask updated Declaration Format is filled out by the supplier and returned to an engineer for review Follow New Part approval process Declaration Format is filled out by the supplier and returned to an engineer for review NO Yes Data is then returned to the supplier for accuracy. Or until material/part is deemed compliant Data is then submitted for input into the database for tracibility If returned second time from suppler and deemed compliant Data is loaded and then tracked and used for further BOM scrubs/queries Yes Engineer reviews and may ask for added information of compliance No action Information is then linked to internal management database, GCM, PDM, ERP etc.. 22 November 2005

23 Impact to Product Structure (BOM) Approval Process One of them not agree T01:BOM Creation Creator T02:BOM Review Eng. Dept Leader T03:BOM Review PP. Dept Leader R01 T04:BOM Approval R02 S01:Set State to Transfer All Agreed Factory Manager All Agreed BOM to ERP System GREEN Review Green Team Admin NEW GREEN CHECK STEP 23 November 2005

24 Impact to Approval Sheet Process T01:Submit to Review Creator T02:Review Reject R02 T04: Approve QA Purchase Section Manager R01 Accept Accept R03 GREEN Review Green Team Admin NEW GREEN CHECK STEP T03:Approve Department Manager Reject Accept A A N01: Notification DCC Creator 24 November 2005

25 Impact to Engineering Change Process Document Template: Approval Sheet Spec Lifecycle: DocLC-24 Cross02 Workflow:Type-24 Cross02 Set State to Updating Part and ERP GREEN Review Green Team Admin INSERT NEW GREEN CHECK STEP 25 November 2005

26 Impact to Supplier Database Process Supplier Approval/Review Workflow QE/QA creates Audit Report Reviewer Approval System notify Sourcing Admin. Released Notify members GREEN Review Green Team Admin INSERT NEW GREEN CHECK STEP Manual Sourcing Admin. Updates Supplier status Business Entity Supplier Supplier attributes Approval Status Approval Status Doc No Status Update Date Approved Till Green Status (NEW) 26 November 2005

27 Operational Scenario New Part Checking Process 27 November 2005

28 Customer Provide Product Spec (Eng Spec, Green Spec) Overall Operation Scenario Spec CE, QA Create and Review Spec (Eng Spec, Green Spec) Regulation PDM GCM R&D Design Green Product based on Green AML R&D Apply new part with data sheet provided by vendor Part Data Sheet CE Initialize Component Approval Process IQC Check the component Green status CE Get Survey Form from Supplier Portal IQC input verification data (XRF, ICP,...) Survey Form & Testing Report (Sub Part & Substance) IQC Testing Data R&D issue Design Change R&D issue modified mold design, drawing through supplier portal CE issue new survey form for modified component through supplier portal Revised Survey Form & Testing Report (Sub Part & Substance) CE get new survey form for modified component through supplier portal 28 November 2005

29 R&D Search PDM for Green Part 29 November 2005

30 R&D Apply Part Number For New Green Part 30 November 2005

31 Once Part Number Is Generated In PDM, Then Registered Into GCM Through Workflow Robot No Information from Supplier yet 31 November 2005

32 Green Administrators Initialize Part Approval Process 32 November 2005

33 GCM System Sends Survey Form To Supplier Based On Part Type (Classification) 33 November 2005

34 Suppliers Are Notified With Access To GCM Via Attached Web Link 34 November 2005

35 Suppliers Upload Survey Form And 3rd Party Testing Report Through Green Portal To GCM 35 November 2005

36 Green Team Reviews Based On Classification And Rules (Regulation) 36 November 2005

37 Green Team Reviews Survey Form And Testing Report 37 November 2005

38 Verify Part Green Status Based On Regulation Through GCM 38 November 2005

39 System Notifies Supplier Of Review Status Via Green Portal 39 November 2005

40 PDM System Updates Part Green Status 40 November 2005

41 PRODUCT SPOT CHECK PROCESS Section 3 41 November 2005

42 Product Spot Check Process Objective To assure that suppliers are meeting the Green environmental requirements concerning hazardous and banned materials use the Product Spot Check Process 42 November 2005

43 Product Spot Check Process Implementation Spot Check Process Involves guidance from other groups regarding the selection, validation, recommendations regarding part control, disposition in the Green database, and follow-up actions with suppliers. Random Sampling Process Utilizes minimal guidance in the selections of parts and a limited suite of tests to be run in the Authorized or outsourced Materials Lab. This process is intended to act in a manner similar to an environmental watchdog agency where part selection is not predetermined 43 November 2005

44 Product Spot Check Process Details The Spot Check Process verifies documentation support Review the Product Content Declaration and then gather evidence to support the declaration. Compliance support work includes a review of the declaration responses against the listed requirements; reviewing a supplier s corroborating evidence; and ultimately (if needed) a sample part laboratory evaluation. The Random Sampling Process verifies compliance by sample testing Accomplished by a sample part laboratory evaluation (using a specially designed set of tests) and then checking the results against the Product Content Declaration. Additional work will be required if the laboratory sample part test and the declaration don't agree, or the part does not meet the listed requirements. 44 November 2005

45 Product Spot Check Process Assumptions Involvement of following groups - Spot Check process owner (Quality Control Group) - Procurement Engineer - Materials Lab - Component Engineer - PEP Coordinator - Green Team Lead Exclusions Prior to 2006 Green implementation - Spare parts for old systems are not involved - Parts to sunset are not involved Random Sample Testing - All Green requirements are applicable - A subset of all required tests will be identified as primary tests - A focus will be given to specific tests (e.g. mercury, lead) as necessary 45 November 2005

46 Product Spot Check Process 46 November 2005

47 INCLUSION OF GREEN IN THE LIFECYCLE CHECKPOINT PROCESS Section 4 47 November 2005

48 New Product Development Process: Event Driven Formal Decision Check Points (DCP) In Work P/N Request Release Item to ERP BOM Creation Release BOM to ERP Active Rework Green Part DCP Green BOM DCP Green Report DCP Green Supplier DB DCP Current PEP/Green Activities in New Product Development Prior to Plan DCP: Environmental Requirements are to be considered in high level design Early in Develop Phase: Initial PEP is to be completed (will include BOM review) Prior to Develop/Verify Exit: PEP is to be updated (will include BOM review) Prior to Availability DCP: PEP is to be completed (includes final Green review) At Availability DCP: Completed PEP is Checklist requirement 48 November 2005

49 Potential Environmental Additions to NPD Add BOM Review requirement to MRR (Manufacture Readiness Review) checklist - No formal Check Point at Develop/ Verify exit - A formal checklist requirement prior to Availability is preferable Add an Environmental and Recycling impact assessment (yet to be defined) to Plan checklist 49 November 2005

50 Environmental Data Tracking Of New Part Numbers Created In PDM Section 5 50 November 2005

51 Environmental Data Tracking Of New Part Numbers Created In PDM To ensure compliance to environmental directives, the Green team is tracking percentage filled-in, of the following four PDM environmental fields on newly created part numbers in PDM: PN has Prohibited item PN has Non-lead Green item PN has Reportable item PN is Lead-Reduced The PDM part numbers are assigned to a Divisions. Divisions are assigned owners to insure their business units are working to populate these four fields. The reports show : Percent filled of part numbers created greater than 90 days Current to 90 day old part numbers split by Division All part numbers without the environmental fields filled in sort able by Division, Data Provider, Release Org, Engineer, and Manager. 51 November 2005

52 Environmental Data Tracking Of New Part Numbers Created In PDM (By Division) 52 November 2005

53 Environmental Data Tracking Of New Part Numbers Created In PDM (Sub System) 53 November 2005

54 Environmental Data Tracking Of New Part Numbers Created In PDM (By Person) 54 November 2005

55 End To End Green Data Management Process Make Compliance A Part Of Your Process Accurate Data Enable suppliers to provide all required data in a consistent format via the Product Content Declaration form. Efficient Method for Collecting Required Data Part of PDM Checkpoint Process for Developing Products, Ensures compliance verification of Products prior to announcement date. Rapid Response Capability for Audits Be able to respond rapidly to audit requests, Prevents downtime should governing bodies or customers request an audit of a product for reportable or Green substances. Reduces potential fines or limits time that fines or stop ships would be in effect until compliance proved. 55 November 2005

56 End of Presentation 謝々 Thank You! 謝々 Joseph Tang Business Consulting Services, Industrial Sector, IBM Taiwan Tel: (02) Mobile: F, No. 7, SongRen Rd., Taipei, Taiwan 56 November 2005