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Second Candidate: A High-end Enterprise Package
PS/HTL next identified a high-end package where electronic kanbans were merely one component
of a large-scale end-to-end ERP system. A team of consultants from the software vendor came to
PS/HTL to train Gintz and guide her in setting up the system. Four days into the training and a
long way from having their kanbans set up, Gintz realized this was application overkill. “I’m a
highly experienced systems analyst,” she concluded, “and if I don’t understand it after 4 days, the
buyers, planners, and suppliers aren’t going to either.” The package’s sophisticated forecast tools
and forced specification of complex parent-child relationships offered no added benefits, only
added cost, startup time, and maintenance overhead. Proceeding with the implementation was
likely to handicap manufacturing efficiency for months.
In the meantime a 20-minute webcast demonstration of Datacraft Solutions’ Signum product had
alerted Gintz to a system that aligned perfectly with what PS/HTL needed: To put in place a
system that was easy to learn and use for buyers, planners, and suppliers, and visible enough that
everyone involved could do their jobs without constant confusion and supply worries cutting into
productivity.
“It did everything I’d seen in the solution from our sister company,” Gintz said, “but without the
big development effort at the front end, and the ongoing support headaches on the back end.”
The PS/HTL-Datacraft Solutions Kanban Automation Project
Datacraft Solutions and Gintz approached their work together as a project with measurable goals
and a clear, phased implementation strategy. These were some of the specific goals PS/HTL
targeted:
􀂃 Be assured of getting what’s ordered, and only what’s ordered, at the expected date
􀂃 Handle the unpredictable—spikes in demand and other exceptions—predictably
􀂃 Get a clear picture of the health of every cell and kanban at any time
􀂃 Automatically calculate expected-on-dock delivery dates based on replenishment lead times
􀂃 Rapidly bring suppliers on board and provide them visibility of the kanbans they support
􀂃 Shorten replenishment times based on true schedules rather than one-size-fits-all guesswork
􀂃 Evaluate and motivate supplier performance based on accurate tracking of delivery times and
quantities
Phased Introduction: Roll Out by Product Line
PS/HTL decided they would roll the system out in phases, beginning with product lines involving
about 20 key suppliers and the most out-of-control paper fax releases, then phase in the remainder
once the fax-eating “cookie monster” was under control.
Rapid Training: Datacraft consultants provided initial training to Gintz in a 1-hour session over
the web. Gintz, in turn, trained her buyers, and associates, who caught on quickly thanks to the
system’s intuitive, visual web interface and its instant window into kanban and cell health.
System Setup: Automating the paper system involved translating fax sheets into electronic
signals. Signum’s streamlined approach facilitated rapid setup because the system didn’t force
defining complex parent/child relationships (though it did offer the choice if needed) or entering a
product’s entire bill of materials to get started.
Supplier Training: Together, Gintz and Datacraft conducted training for the initial group of key
suppliers, who Gintz describes as “…so fed up with the paper system I knew they’d be willing to
try something new.” [more]
􀀵 Total time from project inception to live launch: 8 weeks.
“What led us to decide
to go electronic was
sheer frustration—and
the need to start
managing instead of
reacting.”
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Tips for Success from PS/HTL’s
Cari Gintz
“The most critical element
in our success was a solid
definition of our process flow and
Datacraft Solutions’ quick grasp of
our business processes. We’d
done our homework in mapping out
the flow, documenting it, and
making sure it was well understood
by our buyers, associates,
suppliers, and Datacraft. We
actually produced a Visio flow
diagram showing exactly how a
card moves from one place to the
next and eventually back home.
“Without this pencil work
there is no way we could have
successfully launched the
automation process and supported
our high volume of parts and
　
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