IBM Systems Magazine, LANSA Review- May 2014 - LR5

lines could become a safety hazard cluttered
with boxes and parts. The freed-up space also
allows for more flexibility, opening up the
possibility to produce additional models on an
assembly line."
"When we started the project we did an
ROI analysis.We use up to 4,500 cards each day
and 8 to 10 people would get involved in each
kanban cycle. Based on the card being handled
on a average 10 seconds each time and average
wages being $30 per hour, we estimate to save
$3,000 per day, or $747,000 per year, in labor
costs directly related to staff not having to
handle the manual kanban cards."
KMM expects to save another $190 per day,
or $47,500 per year, because there is no need
any more for someone to walk around cutting
a slit into each box and inserting a card. Now
barcoded labels are printed and affixed to the
box. Other estimated savings include reduced
labor for analyzing part shortages 5 hours per
day and for running hot parts 16 hours per day,
adding up to more than $155,000 per year.
"We believe our ROI on eKanban is going
to be very short, less than six months," says
Kamradt.

More apps and more savings
The LongRange tutorials, together with their
first working app as a best practice example,
provided enough training for KMM's developers
to start on their next mobile project.. A team
of 3 IBM i developers built 5 more apps. All the
apps are native, touch-enabled with dropdown
lists, check boxes, buttons to start the scanner,
and so on. The apps were implemented at the
first assembly line 2 months into the project
and soon after at the other lines..
An app for scrap reporting allows assembly
supervisors to scan in scrap items throughout
the day and, where needed, enter comments.
Previously they would compile a handwritten
list at the end of the day of the items they found
in the scrap bin. Then a clerk at the quality
control department would spend most of a day
rekeying the lists from all 4 lines.
"Automating the process using mobile
technology saves our quality department a lot
of time and makes the information that we
track far more accurate," says Kamradt.
An app for cycle counting allows workers
to adjust the inventory while on the floor
and generate a pick ticket if needed. Another
app allows workers to record the moving of
inventory within the warehouse. Previously
these movements were simply not recorded,
because there was no workstation on the
floor. Workers would lose time trying to locate
misplaced inventory. Now the recording of
inventory is far more accurate.
An app for online/offline reporting lets
the assembly line supervisor scan when an

Jay Kamradt, Information Systems Supervisor at KMM, next to an assembly inventory specialist
using her iPad with the LongRange developed apps.

"Users on the floor find the
LongRange developed apps
intuitive, reliable and stable."
assembled unit needs to be pulled off the line
for repair and enter the reason. "In the past
those units would just sit next to the assembly
line and it was unclear when they got there or
why. The real-time recording results in better
quality control," says Kamradt.
An app for engineering change notifications
(ECNs) allows for the real-time recording of
when a changed bill-of-materials comes into
effect. "If anything comes up from a quality
standpoint, we now know exactly which VINs
(Vehicle Identification Numbers) are affected,"
says Kamradt.

apps are intuitive, reliable and stable.We haven't
had any issues or a need to revisit code. We
developed the apps, they are in production and
they have been running fine. The apps are now
a crucial part of our new procedures and we
cannot run the assembly plant without them."
"Over the years we dedicated a lot of IT
resources to make things better for the office
workers. The production area is where we
make our money and we decided that it's
time to start improving their processes. What
we have done today is just the beginning,"
concludes Kamradt..
"My advice to other IBM i shops is to jump
in with both feet to provide users with mobile
apps. It won't take you long to realize the
benefits." n
View a short video on this project at:
www.lansa.com/kawasakivideo

Conclusion
Paul Kramer, Assistant Manager Information
Systems, explains "Using in-house skills, we
initially thought our only choice was going to
be mobile Web apps, but that would have made
it more difficult to use an external scanner and
would also be less user friendly. Mobile access
is only part of the eKanban puzzle, but it is a
very visible and essential part. With LongRange
we were able to handle the entire project
ourselves, including mobile access."
"Our developers found LongRange easy
to learn and development was fast. We got
our first series of apps out in just 2 months,
including installing, going through the tutorials,
development, testing and implementation," says
Kamradt.
"As far as the users on the floor, their
experience is that the LongRange developed

www.LANSA .com/Su bscribe

Snapshot
Customer: Kawasaki Motors Manufacturing Corp,
USA Consumer Products (KMM).
www.kawasaki.com
Challenge: As part of an eKanban system, KMM
needed to develop a series of mobile apps running
on iPads that could integrate with the corporate
ERP system and access an external scanner.
Solution: Use own in-house development team
and existing skill-set to develop native apps with
LongRange.
Key Benefits: Savings of $3,500 per day in labor,
safer and uncluttered assembly lines.
Product Used: LongRange.

5


http://www.lansa.com/kawasakivideo http://www.kawasaki.com http://www.LANSA.com/Subscribe

IBM Systems Magazine, LANSA Review- May 2014

Table of Contents for the Digital Edition of IBM Systems Magazine, LANSA Review- May 2014

IBM Systems Magazine, LANSA Review- May 2014 - LR1
IBM Systems Magazine, LANSA Review- May 2014 - LR2
IBM Systems Magazine, LANSA Review- May 2014 - LR3
IBM Systems Magazine, LANSA Review- May 2014 - LR4
IBM Systems Magazine, LANSA Review- May 2014 - LR5
IBM Systems Magazine, LANSA Review- May 2014 - LR6
IBM Systems Magazine, LANSA Review- May 2014 - LR7
IBM Systems Magazine, LANSA Review- May 2014 - LR8
IBM Systems Magazine, LANSA Review- May 2014 - LR9
IBM Systems Magazine, LANSA Review- May 2014 - LR10
IBM Systems Magazine, LANSA Review- May 2014 - LR11
IBM Systems Magazine, LANSA Review- May 2014 - LR12
IBM Systems Magazine, LANSA Review- May 2014 - LR13
IBM Systems Magazine, LANSA Review- May 2014 - LR14
IBM Systems Magazine, LANSA Review- May 2014 - LR15
IBM Systems Magazine, LANSA Review- May 2014 - LR16
IBM Systems Magazine, LANSA Review- May 2014 - LR17
IBM Systems Magazine, LANSA Review- May 2014 - LR18
IBM Systems Magazine, LANSA Review- May 2014 - LR19
IBM Systems Magazine, LANSA Review- May 2014 - LR20
IBM Systems Magazine, LANSA Review- May 2014 - LR21
IBM Systems Magazine, LANSA Review- May 2014 - LR22
IBM Systems Magazine, LANSA Review- May 2014 - LR23
IBM Systems Magazine, LANSA Review- May 2014 - LR24
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