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Enhancing Quality with SYSPRO QMS
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Everyone, welcome to this webinar on SYSPRO's Quality Management System or QMS. I am Steve Bassaw. I'm with SYSPRO Americas and I'll be your host in today's webinar. You will get a recording of the webinar after and you will get a copy of the slides as well. And also, if this is important, if you would like to ask questions, could you please, in Zoom, use the Q&A button to ask your questions, not the chat button. It's because that's where we are capturing questions. In the Q&A, not in the chat. And we will address your questions at the end. If we don't get to all the questions, we will get back to you by email as well. Okay, so let's get going. SYSPRO QMS. It's an exciting new module and set of features in SYSPRO in quality management. Let's talk a bit about it. So what is it? It is a new module in SYSPRO, relatively new. It was actually released in the SYSPRO 8 2023 release. And as you can probably surmise, it manages all your quality-related activities. It's a quality management system and gives you real -time visibility of all your critical quality metrics. And a little more about it in terms of where does it fit in terms of the other SYSPRO solutions around quality. And so first thing to note is that it's not intended to replace our partner quality solutions. You might be aware that SYSPRO has partner solutions in quality, pretty advanced solutions, and we're not trying to replace those. What we're trying to do is provide light to mid-level or medium level of quality management functionality in SYSPRO. And we'll talk a bit more about that in the coming slides about what quality management features are in SYSPRO right now before this module was released. And what does this module give you on top of that? Okay, so let's have a look. Now, you might be aware that in SYSPRO, even before the quality management system was released, there was what I'm calling the standard or PO or WIP job inspections. Those have been in SYSPRO for a very long time. Those are still there. You can still happily use those without using the QMS system. What do they do? As you can see in the box there, these standard inspections allow you allow you to inspect, say, allow you to inspect, say, after receiving a PO or after receiving a job, you can put it into an inspection phase. And inside of there, you can do some basic, simple things like count. How many did we receive? Record that you've inspected the items. And then what did you do with them? Did you scrap them? Did you reject any? Did you return them? Did you accept them? So there's a little simple workflow in there where you can walk through those phases of the inspection. What you could not do is actually capture metrics, quality metrics like tolerances and other measurements along the way. So it was a fairly simple, straightforward, but functional and useful functionality. And it's still there in SYSPRO. And in contrast, we now have the QMS system as well, which builds on top of that. So at a super high level, the QMS system provides you with more sophisticated features. It manages all of your quality related activities up and down the supply chain. So suppliers to customers, the whole works, and gives you full visibility and audit trails of every quality related activity. So let's take a little bit of a deeper look into that. So the quality management system is broadly based or consists of these four components. And one is the inspection engine. And that allows you to design more sophisticated types of inspections than the basic inspections we talked about earlier. Number two, you can perform non-conformances and corrective applications. So if an inspection fails. So if an inspection fails. So if an inspection fails, you can actually run through the NC process and record all of that. That is actually a future functionality in the QMS module. It's coming out approximately in the fourth quarter of 2024. Thirdly, recall management. So QMS features a recall management feature where you can actually do recalls of product. And we'll see more details on those later. And that too. And that too. The customer complaint system was already released a few years ago, but it's now inside the QMS module. So let's go into each one of these four areas and explore what they do. That's what the main purpose of today's presentation is. So first, there's the inspection engine. And high level, what does it offer you? So as I mentioned, the features, it allows you to create your own custom test plans. You decide what you want to measure when you're doing inspections. Secondly, you perform the inspections after the PO receipt. So a PO comes in or after you've completed a job and done the job receipt. A point to note there is that the QMS system currently does not support doing inspections during the manufacturing process. So what we call in-process inspections is a PO. In-process inspections is a PO. In-process inspections, like if you have a job with multiple operations, the inspection kicks in at the end of the job, not at the point of each operation. If you need that level of inspection, then you can talk to us about looking at one of our advanced quality solutions, which actually does that. And lastly, you'll see on the left there, there's the inspection dashboard. So you have a view of what's going on with the inspections. And the benefits to you. And the benefits to you are pretty self-explanatory. You can set your own quality control standards. You can reduce variability. Well, that's actually the whole point of manufacturing and quality is to make the same product over and over without variability. And that leads to the third point, which is reduce costs from rework and scrap. And I'll tell you a quick story. You know, I used to work in a manufacturing plant myself. And there's been times when we had rework and scrap because something failed the quality check or we didn't have a good quality management system. And it costs a lot of time and money. A second story. One time I was touring a customer's plant, a big manufacturer of industrial equipment. The owner himself was touring me through the plant and he pointed to an industrial pump sitting there on the shop floor and it had a lot of dust gathered on it. And I said, what was that? And he said, actually, that's an industrial pump we made for somebody, but we made it to the wrong spec. And that's $6,000 of labor and materials wasted. And they had a couple of examples of those sitting around, right? So the amount of money from actually not performing your quality inspections well up front and being proactive is quite significant. And lastly, relating to all of this, of course, is customer satisfaction, right? If you have, it's just obvious, less defects, you're going to have better customer satisfaction. So on the next slide, we'll talk a little bit more about the inspection engine and a little more detail on it. And so here we have some of the components of the inspection engine. So we mentioned there's the dashboard and you'll see some screens of these coming up in a second, by the way. So in the dashboard, you can view what are your test results and the quantities, and you can have a drill down into the results as well. Secondly, there's a setup involved in using the inspection engine and some of the components you would set up or you design your own inspection plans. What do you want to inspect? What measurements do you want to capture? You can capture those fairly granularly. So you can say, for example, per stock code or warehouse or customer service, supplier, it's a different inspection plan, it's a different inspection plan for say one stock code in one warehouse versus the same stock code in another warehouse or for a different supplier. So you can get fairly granular there. For any type of test you set up, you can have your acceptable limits or tolerances. You can also specify sampling. So when I do the test, do I want to test just a sample of the whole quantity or the entire quantity? Or say just one or whatever. And lastly, you can have reason code. So if something fails an inspection, you can have reasons, which you can analyze later. The third box on the slide is then actually doing your processing, which is doing the inspections. So you can assign the inspections to users. And then they would actually go in and perform the inspections to see whether it passed or failed. And let's look at a screen of what some of this looks like. We have a couple of screens coming up. So here's one of them. This is the inspection test design screen. And you'll see the red box there in the middle. This is just an example of how you could design your own measurements to be tested in the inspections. And so what we have there. If you look at the first one is a visual inspection, a pass or a fail. So that's a, we've set that up as a dropdown. It's going to be a yes or a no for whoever performs that test. Another one is certifications received from the supplier. So that one, we set that up as a checkbox. And the last one is record the supplier's packing list number. And that's an alpha. You can also have numeric numbers as well. Numeric measurements as well. And if you look over on the lower right of the screen, you'll see the tolerances there. So alpha and numeric tolerances, for example, you can see the upper tolerance, the lower tolerance. So this is how you would design your own type of inspection tests. And as I mentioned, you can design these differently for different stock codes, warehouses, et cetera. And then you would actually go into a test queue. So this is where somebody will actually go and do the work and perform the inspections. And so what they do is you'll see the box at the top left. There are filters you can apply here. Lots of them. We'll just talk about a couple of them. One is, do you want to view the queue for whip job inspections and or PO inspections and a whole bunch of different statuses on the inspections. And at the bottom left, you'll see warehouses. And all of that. So you can filter the list to see just the inspections you want to see. And then in the top middle of the screen, you see the sample tests. So those are for this PO, for example, this the types of inspections that we need to do on this PO receipt. And if you drill down from the top red box to the bottom, red box, you can see for that inspection, you can see for that inspection, you have the actual test that you need to do. And you can have multiple tests, tests there as well. I only have one here, but you can have multiple. The next step after reviewing your queue is actually to perform the inspection test. And so if we jump ahead, we'll see we go into the inspection test measurement screen. And there we depending on what the question is, we answer the question in this case, it was a pass or a fail. So we're given the options for a yes or a no. If it were numeric, we would record say the temperature or the diameter or whatever recording. These will be question specific, and you'll provide the answers. And then you'll finish your inspections. And you can save these and come back to them. Or you can submit them to say I'm done. And then on the next screen is the dashboard. So this is where management can see what's going on with this inspection. And I'll just walk through different parts of the dashboard here. So if we look at this red box, that's what type of inspections is this one? Is this a PO inspection or a WIP job inspection? And in the middle of the screen? And in the middle of the screen, various data about the inspection? What's the PO number and the supplier and did it pass and other data like that? And over on the right, you'll see the quantity. So how many have we do we have an inspection and have we tested so far? So we've actually passed two out of the 10. And on the bottom left, we have what are the inspection tests that that were performed here. And you can see that in green, these two types of inspections actually both ended up passing. And so you have quick visibility of that. If any of them failed, they would be in red. And over on the right, there's a drill down on that. So for those inspections that were performed, what were the individual tests that were done? And you can drill down into the results of the individual tests. So this is a nice dashboard to see all the data you need to see about this particular inspection. Okay, so that's a quick overview of how the inspections part of the QMS module works. And now we're going to shift gears into another component of the QMS module, which is the recall management. So recalls are, as you probably guessed, are the ability to do product recalls. And we know how important that is. You've probably heard in the news lots of times about food being recalled or airplane problems, parts being recalled. Or, you know, recalls are a critical thing to manage properly. And so on the left, you'll see some of the recall management module. And so you can do what we call full recalls or mock recalls. And what's the difference? We'll talk a bit more later. But full recall is an actual recall you're doing for real. A mock recall is just to prove that you can do a recall. In a mock recall. In a mock recall, nothing ends up actually quarantined. But in a full recall, it does. Both of these are recorded and saved for audit trails to prove to auditors as well. The third bullet point there, quarantines. You can actually quarantine the goods and say these cannot be sold or used in manufacturing or so on. They're basically on hold. We'll talk a bit more about that in a minute. And you can also identify the affected supply chain. So customers and so on and suppliers. And of course, you have audit trails and reports for all of the recalls. The benefits to you are faster recalls. I mean, I've spoken to some customers out there and prospects as well where their quality management system, it may be kind of manual spreadsheets or some sort of custom older system. And if you ask them how long does it take to do a recall, either driven by themselves or driven by the government or driven by a customer, it can take terribly long digging through the files or digging through worse yet paper. If you can do this at your fingertips in a few minutes, it's a huge time saving and way less stress for everybody in the company. It improves your governance. It improves your governance and compliance, whether it's compliance to the government or the industry that you're in or even your large customers may demand certain levels of compliance and prove that you can recall products quickly. Also allows you to continually test and improve your traceability system. So you can flush out any issues you have as well. And lastly, there's reputational risks, right? You can reduce the risks. We've all heard of companies that didn't do recalls very well. They end up in the news and their brand becomes tarnished. And once you have your brand tarnished, it's really hard to get back the trust. That money can't buy that back. So that's a high level overview of the recall management. Let's dig into a little more detail on it. So the first box, recall items. So what that means is you can put, you can recall or put on hold items that have been manufactured or sold to the customer or inventory that's sitting around on hand as well. And second box is the trace the lots and cereals. So you, CISRO does lot and cereal tracking and you can trace the whole set of movements of the items being recalled through jobs and inventory movements and back flushing and purchase orders. And then you can see the backflushing and purchase orders right from the beginning to the end of the supply chain. You have full visibility of the raw materials all the way to the finished goods that you need to recall. And the last box, quarantine at multiple levels. So what we mean there is you can select different sort of granularities of by say warehouse or bin or stock code of find the items that are need to be recalled. So what we mean there is. So what we mean there is a lot of the records that are need to be recalled by these filters and then quarantine them and say inspect them as well. So fair amount of flexibility there. On the next slide, we'll just see a couple of screenshots of what recall management looks like. So on this screen, you'll see this is a, where you can see the supply chain of who is affected. So in the background, it's a bit blurry there, but what we're looking at is a particular stock code that needs to be a little bit more. So it needs to be recalled, right? It needs to be recalled, right? It needs to be quarantined. And we can easily see in the foreground there, who are the affected customers that we sold this to and what lot numbers and all the other information, what were the affected sales orders as well? And what were the affected jobs? So you can actually quickly find out for an item that has been identified as defective or dangerous or whatever. Where did it go in the supply chain? Where did it go in the supply chain? And then contact the relevant parties. Then you would put it in quarantine and run it through an inspection process, for example, and decide what to do with it. But it all starts here with figuring out where it went. Okay, so that's a quick overview of recall management. And let's go into another area of the software of the quality management system, which is the customer complaint. And so what this is, you can sort of think of it like a service ticketing or a complaint system, where the features are, you can capture customer complaints. So you can open a screen and the customer said, this is defective or broken or whatever. And you can record the details. Secondly, you would investigate that and determine then the actions and the resolutions to solve the problem for the customer. And, you know, the benefits to you are increases customer retention. If you actually have an ability to track these things and be proactive with the customer and show them that you're working on the issues. A lot of times, even if a customer reports an issue, the way you deal with it determines whether you keep the customer or not, right? Often customers are, they'll forgive a couple of issues here and there as long as you dealt with it well. But if it goes into a black hole, they're not going to put up with that for very long. So secondly, it drives continuous improvement by having these recorded. You can actually determine where are we going wrong here? Why are we having this problem over and over again? Is it an internal problem? Is it a problem with our supply chain? Maybe the materials from the supplier. So it gives you some visibility to improve the process, which then improves your product quality and also gives you insights into if it's a supplier issue or not. So what are the complaints related back to that? All right. Next slide. We'll talk a bit more about the customer complaints. Some of the components are building blocks of the module. And so first box, you'll see there is users roles permissions. And what that means is you can assign, you can create a set of users with permissions in the customer complaints module who will handle the complaints and they can do things like escalate to others and so on. There's also second box, a complaint process flow. And you'll see that in a minute on the next slide. And lastly, you have reporting and audit trails. So you can see what happened. All right. So let's go to the next slide and take a look at that. And so the process flow for the customer complaints is number one. You capture the complaint and some of the data you can capture. You can see there are things like the severity, the summary of the problem, the details of the problem, including attachments, including if optionally a link to the original invoice or the sales order. Also, there is some basic email notifications that can be sent. So for example, when you open customer complaint and save it, the customer can be notified by email automatically upon the save. Operators internally can be notified that it's in their queue as well. And similarly, say when you're closing the complaint ticket, people can be notified, whether it's the internal people or the customers as well. So the second box you'll see there, the assign to the users. So a manager, for example, can assign the complaint to a user to work on. And there's also the concept of groups. A user can belong to a group like the QA group or the sales group or whoever. And there are groups can have owners, which are like the managers of the group who can manage things like escalations or they can take over the ticket if they need to. So that's what an owner does. And then the third box, of course, is you investigate. Well, what went wrong? And importantly, you can record your activities. And there's an audit trail of that. A user could optionally reroute the ticket to someone else if they need help or they're busy. There are also automated escalations. So there's a, if for example, the ticket's been sitting around unaddressed for X number of days, it can automatically escalate. So you can get to somebody. And lastly, the last box is resolution. So you would eventually close the ticket. You can give a reason code of why did the problem happen. And optionally, you can reopen the ticket if the customer asked to reopen it if you needed to. So let's just take a look at a couple of screens of what the customer complaints process looks like. And here's one. So this is the complaints entry screen. And it's probably as you would expect. So you're entering who is the customer? What is the problem they're reporting? You'll see at the top left, there's a priority field. There's a description field. And at the top right, there's documents like, or sorry, link documents, like is it linked to an invoice or a sales order? All sorts of information that you would capture here against the customer and the complaint. And then someone would work on it. And they would actually investigate. And those activities would be recorded. So that's on the complaint activity screen. So that's on the complaint activity screen. And here you can see there's several activities listed there and who did what and when. So that's really important for continuity. So and also just for audit trail. So we know where this is at right now. Everything is time stamped and date stamped as well. And eventually you would close the ticket. And that would be resolved. Okay, so that's a quick overview of the customer complaints. And then another component of the quality management system is the non-conformances and corrective and preventive actions. And as a reminder, this is coming out in later in Q4 of 2024. And here are some of the features on the left. And I guess before we dive into any of those, this is the process flow is if we did an inspection in the inspections part of the QMS system, and say it failed, we might want to raise a non-conformance, which then also may involve corrective actions and preventive actions for the future. And that would be the flow, right? That inspections would hand over to non-conformances and CAPA. And so you can have a manual or a trigger non-conformance creation. You can route it or assign it to different users to work on it. You can capture the investigation details. You can create your plans for the corrective and preventive actions. And then you can have audit trails of the whole thing. And benefits to you on the right side of the screen. Detect the issues early and reduce escalations. We talked about that before, about being proactive rather than reactive. Improve your processes. Again, reduce your costs, rework and downtime and consistent product quality. So that's coming in, as I said, Q4 of 2024. More details to follow in the future. And that pretty much wraps up an overview of the QMS system. There's one more thing I wanted to mention here. You'll recall that I said that a couple of the features of the QMS, the recall management and the customer complaints, have been out for a couple of years already. And they actually have moved. And they actually have moved. So you'll see on this slide, the recall management on the left used to reside inside the lot traceability module. But now it has moved into the recall management, sorry, into the quality management module. Similarly, the customer complaints feature used to live inside the contact management module. And it has now moved into the quality management module. If you are already using recall management or customer complaints. You are not required to license the quality management system or pay any fee. You will continue to be able to use those modules. And if you have any questions about that, contact your account manager. We have documentation that can explain how that works and the account manager can explain it. But the most important thing is if you're using those already, you don't have to pay any additional fee. It's just that they get moved into a different module. All right. And that actually concludes our webinar on the quality management system. So I hope you enjoyed that. And what we're going to do now is I'm going to see if there's any questions in the question panel here. And let's see. So, you know, we have a couple of questions here. So one person, said, I see that you're showing the CISPRO web interface. And by the way, in case the web interface used to be called CISPRO Avanti, which is just refers to another name for the web UI. So just a clarification for the person asking the question, this Avanti you refer to is just our CISPRO web UI in CISPRO 8. It's the same CISPRO as the one you're using, say, in the client. And your question is, are the features and interface the same as in CISPRO 8? I think you mean in the Windows client. The answer is yes. The CISPRO web interface I have been showing in these screenshots today is the same product as the CISPRO Windows client that many of you are using. It's just a different interface. It runs in a web browser. But it performs all the same features under the hood. They're the same product, same code, everything. Hope that answers that question. Another question. Can you create, attach or attach inspections for work orders created through CISPRO? So the answer to that would be yes. As mentioned, what happened there is the inspection of a work order kicks in upon the completion of the completion of the work order. So when, specifically when you do the job receipt. And then you're saying, okay, I finished the job. Now let's do an inspection on it. Another question here, can you attach files to inspections? I'm pretty sure you can. I'd have to go back and look, but I'm pretty confident that you can. We'll double check that, but I'm quite sure the answer is yes. Let's see some more questions. When will the features of QMS be released? Okay. So let's recap that. The QMS module itself with the inspections, with the recall management, and with the customer complaints are all released right now. The inspection part of it was released a year ago, and the complaints and the recall were released a few years ago. So all three of those pieces were already released a few years ago. So all three of those pieces were already released and can be used right now. You have to be, of course, on the version of CISPRO 8 2023. And by the way, there's a 2024 version that's coming out now, and you don't have to be on that one. But if you want the non-conformances, that will be in the 2024 release. Right? So just to recap, all of the functionality, the I'm not sure of the question, but when does the lot number include it in MRP? So I think what you mean is like, does the MRP see lot numbers? The answer is yes. There are settings in CISPRO where you can say, and in the MRP module, do you want to consider lot expiry dates or not? I'm not sure if that's what you meant. But if you have further questions, you can contact us or your account manager and we'll dig deeper. I think we might need a further conversation on that. Okay. I'm just checking the questions, see if we have any more. That's all we have so far, folks. I'll just wait a couple more minutes. And if there aren't any more, then we'll wrap it up. So, yeah, but I hope everybody enjoyed the webinar. I hope you see the value of having some inspection functionality and quality functionality inside CISPRO that you never had before, that is built into CISPRO and can provide more functionality than the basic inspections we had in the past where all you could say was, yes, I've inspected it. Yes, I've counted it. Yes, I've accepted some into inventory. This raises the functionality to hire to say, well, now I can actually measure specific things during the inspection. I can see the results of that in the dashboard. I can see the tolerances and so on and the results. So, okay. I don't think we have any more questions there. That was the last one. Oh, maybe, sorry. There's a question. If it's an inspection. Is it seen by MRP? Okay. So, that's a clarification on the MRP question. And so, the person is asking, if the item is in inspection, does MRP recognize that? And I am pretty sure the answer is yes. We can double check that. But in my mind, I'm visualizing the MRP setup option screen. And I know MRP pretty well. And I think there's a checkbox or a setup option there. to say items in inspection to be included or not. But we can double check that just for sure. But I have a fair amount of confidence that the answer is yes. Okay. That's probably the last question. Yeah, I think it is. All right, everyone. I would like to thank you once again for attending the webinar, taking time out of your busy day. As mentioned, you will get the recording. You will get the slides. And if you have any questions, feel free to contact us. Contact your account manager. There's also, well, that's just our concluding slide there. And thank you again. And everybody have a great day. Okay. Bye now.