Robert E. Stein
402 Marigold
Cedar Park, TX 78613
Office: (512) 335-4644 Cell:
(512) 694-1702
Robert_Stein49@msn.com
Robert Stein is a proven hands-on Enterprise and Enterprise One implementer who has been involved as a senior functional consultant in more than 24 implementations of manufacturing and distribution from start through go-live including post implementation support. His implementations usually include the configuration of all manufacturing and distribution AAIs, menus, processing options, versions and the creation/configuration of each branch plant. In addition to performing as a functional consultant, Bob is also a hands-on developer utilizing the Enterprise One tool set and has performed extensive modifications to both manufacturing and distribution systems.
Overview:
Expertise:
Sales,
Purchasing, Advanced Pricing, Inventory, Item Master, Engineering Change
Management, Return Material Authorization, Configurator, Product Data
Management, Shop Floor Control, Product Costing/Manufacturing Accounting,
Manufacturing and Distribution Planning (MRP), OMW Tool Set, Interoperablity.
Revision Levels:
A6.2, A7.3, A8.1, B7.321, B7.3.22, B7.3.3.2, XE, XE.1, XE.2, ERP-8, Ent-1 8.0 Fat and Web, Ent-8.11 Fat and Web
Key Implementations/Industries/Assignments:
Watson Pharma MFG/DIST Consultant and Developer
Merck Pharma MFG/DIST Consultant and Developer
Langer Orthotics MFG/DIST Consultant and Developer
Gateway Computer Manufacturing Sr. Consultant
Zimmer Medical Implant Mfg. Planning and Mfg Accting Sr. Consultant Geospace Geophysical Equipment Manufacturing & Distribution Sr. Consultant Chromalloy Aviation/Defense/Repair Distribution Sr. Consultant
Paoli Furniture Manufacturing and Distribution Sr. Consultant US Motors Electronics Manufacturing - Sr. Consultant
GPC Packaging/Printing Manufacturing and
Distribution Sr. Consultant
CCP Chemical Manufacturing Sr. Consultant
ITC Food Products Manufacturing and Distribution Sr. Consultant Bayco Electrical Appliance Manufacturing and Distribution Sr. Consultant Amgen Pharmaceuticals Manufacturing and Distribution Sr. Consultant
Project Work History:
Watson Pharmaceutical Inc.
Feb 07 – Present
Watson is a multi-billion dollar developer and supplier of state of the art pharmaceuticals with worldwide operations. At present I support the development/configuration and day-to-day operations for their facilities located in Ft. Lauderdale, FL and am involved in the development/configuration/implementation in their facilities in Carmel, NY. My responsibilities also include troubleshooting user problems and creating solutions as a business analyst/functional Manufacturing and Distribution consultant and developer. Additionally, I created a custom JDE/DSI interface to support the RF/Bar code readers involved in Shop Floor Control.
Merck, Inc.
May 06 – Feb 07
Merck is a multi-billion dollar developer and supplier of state of the art pharmaceuticals with 50,000 employees. I have two responsibilities for this project. The first is to support the day-to-day JDE functional and technical operations in the US, Canada and Great Briton by interfacing with users to understand and develop new solutions as problems occur. The second is to implement a heavily modified version of JDE to include Sales Order Management, Capacity Planning, Purchasing and Material Requirements Planning. One of the more significant portions of the implementation includes a Honeywell/POMS interface to JDE via JDE’s Interop system. I am responsible for working directly with the POMS development team to create/modify/troubleshoot the interface from POMS to JDE including Work Orders, Inventory, Sales and Purchasing.
Stoneridge Corp
March 06 – April 06
The Stoneridge Corporation is a multi-billion dollar automotive components supplier to companies like John Deer and International Harvester. The recently hired IT director at Stoneridge and I had
worked together on a previous assignment (Graphics Packaging). A large portion of his IT staff had resigned over a pending move from Warren, Ohio to El Paso, Texas. My responsibility was twofold; the first was as a developer to augment the current development staff in helping them meet a May 1, 2006 deadline for EDI; the second was to act as a functional consultant during a two week study to help the Alphabet division streamline their operations and understand how JDE manufacturing and distribution works.
December
05 – January 06
Roseburg Forest Products is a $1.8 billion company specializing in all forms of wood products for the building industry including lumber, particleboard, veneer, etc. My position was short term to act as a techno-functional resource to aid in after go-live support and augmentation of
the JDE Transportation and Sales Order modules. Tasks included developing applications, writing reports, troubleshooting and fixing data conversion errors. Troubleshooting included reading/correcting code for highly modified applications, changing processing options, developing new functionality to correct problems or developing programs to correct data errors. Data errors included issues such as incorrect unit of measure conversions in the F4111 as determined by running the Ledger/Inventory Balance Integrity report. Application development included activities such as creating a load confirmation report and then auto launching via the approval transaction in the P4915; setting up/configuring new versions of applications within the transportation modules to change functionality or developing security strategies
Langer is the
largest custom orthotic appliance provider in the country. Each orthotic is custom made to a doctor’s
prescription and either shipped directly to the patient or to the doctor. My responsibility is to implement ENTERPRISE ONE sales
configurator, order entry, work orders, shipping and invoicing as a functional
consultant. In addition, I am also responsible for creating/modifying both applications and UBEs
within systems 32, 42, 43 and 31 as well as designing/executing all
testing/specifications to include all control documents, detail test scripts an
result documents. To date I have made extensive modifications
to order entry, work orders and sales configurator. Additionally, I have modified shipping and
have created a warranty system using the One World tool set. I
have also been acting in a functional and technical support role to two other
divisions within Langer. Support includes purchasing, sales,
inventory, shipping, receiving and manufacturing modules.
October – November 03
Created a full explicit pegging system for ENTERPRISE
ONE and eliminated a major flaw in JDE’s MRP strategy that prevents factory
synchronization.
Fleetwood (Enterprise One 8.0)
Fleetwood is the world’s largest manufacturer of
recreational vehicles and runs Enterprise One.
Each vehicle is configured to order and MRP was driven by the
order. The problem they faced in working
with linear feet, as the primary unit of measure for some parts, and because of
the part/BOM configuration, is that MRP would create requirements for raw
material that would be a total requirement and not recommend standard sizes. I created a forecast that used any sales
order configuration as a template to drive a forecast of parts requirements
from configured orders, a cut-list range system that would
add/change/delete/inquire standard sizes for specific parts and created a
cut-list purchasing report that would take the gross requirements of MRP and
break them down into standard sizes.
Amgen (World 8.0)
June – August 03
Amgen is a large manufacturer and purveyor of state of the art medicines. My responsibilities include test/trouble-shooting conversion (World 7.3 cum 4 to 7.3 cum 13) and functional applications as well as monitoring go live processes including the accounting, manufacturing and distribution modules. Wrote the cutover plan including pre-cutoff, cutoff, validation and go-live
activities. Key issues include the definition of activities, scheduling, the
coordination for logistics and accounting, and creating/executing the go-live
validation checklist. Reported to the
project manager with a dotted line to corporate.
Product Development (Enterprise One)
March – June 03
Developed a finite scheduling system for ENTERPRISE ONE
that focuses on synchronization and is based on a book that I published under
Marcell Dekker Publishing, June 03, entitled Re-engineering the Manufacturing
System 2nd Edition. In
developing the system I used the One World tool set. The benefit in doing so is that the system is
an integral part of the One World Manufacturing System. My basic premise is that optimization and
synchronization are not the same thing and that optimization systems disrupt
synchronization. 99% of all factory
scheduling systems today focus on optimization.
Graphic Packaging (Enterprise One)
Graphic packing is a large printed packaging business with
$1 billion in sales and 18 manufacturing facilities running ENTERPRISE
ONE. My responsibilities included
implementing manufacturing and distribution as well as product development,
monitoring/trouble shooting the manufacturing
and distribution go-live processes, making/recommending changes to the setup,
designing/executing CRP and testing scripts and solving technical/functional
problems. I was also involved in the setup/configuration of a number of
activities that were not part of the original system setup such as outside
processing, advanced pricing, material return authorization and materials
management (MRP) with a Synquest interface.
Zimmer, Inc (Enterprise One)
February 02 to May 02
Zimmer is a medical implant company with over $1 Billion in sales running ENTERPRISE ONE. My responsibilities included acting as Sr. Consultant in defining/configuring the planning strategy for 4 manufacturing facilities in the US and Puerto Rico. Modules included were configuring/troubleshooting Manufacturing Planning (MRP) for a Multi-plant Strategy and Manufacturing Accounting for all facilities. Configuration included all versions, menus, AAIs, testing and troubleshooting. In addition, I wrote several custom applications and reports using the OMW tool set. I was also responsible for analyzing and developing specifications for any modifications that affected my area of responsibility including interfaces and conversions.
Oyo-Geospace (Enterprise One)
August 01 to December 01
Oyo-Geospace is a conglomeration of 4 different companies with 4 very distinct product lines including geophones, printers and engineering services running ENTERPRISE ONE. Each company had very different requirements. I joined the project with two months left on a 5-month project and very little accomplished. My mandate was to get the project back on track and to meet the original due date. My responsibilities were to configure, test, troubleshoot and train the
trainers for all manufacturing and distribution modules including Sales, Purchasing, Inventory, Item Master, Return Material Authorization, Service Order Management, Warranty and Repair, Product Costing, Manufacturing Accounting, Shop Floor Control, Forecasting, Material Requirements Planning (MRP), Product Data Management, Time and Material Work Orders and Engineering Change Management. Tasks included configuring all AAIs, Menus, Versions and creating or modifying reports and screens. Starting from scratch, in 2 months I configured all manufacturing and distribution modules for the 4 companies and was able to meet the project managers original due date. I was also responsible for analyzing and developing specifications for any modifications that affected my area of responsibility.
Paoli Furniture (Enterprise One)
March 01-August 01
Paoli Furniture is a $300 million dollar division of a $1.1 billion furniture manufacturer running ENTERPRISE ONE. My responsibility was to configure, test, troubleshoot and train the trainers for all manufacturing and distribution modules including Configurator, Sales, Advanced Pricing, Purchasing, Inventory, Item Master, Return Material Authorization, Service Order Management, Warranty and Repair, Product Costing, Manufacturing Accounting, Shop Floor Control, Forecasting, Material Requirements Planning (MRP), Product Data Management, Time and Material Work Orders and Engineering Change Management. Tasks included
configuring all AAIs, Menus, Versions, creating or modifying reports and screens, developing/executing all CRP and test scripts. I was the only consultant on the project. In 1 month I had configured the first prototype and within 4 months we were ready for go-live. I was also responsible for analyzing and developing specifications for any modifications that affected my area of responsibility.
County of Sheboygan (Enterprise
One)
December
01
The County of Sheboygan Road
Management Department was having difficulty configuring their ENTERPRISE ONE
system. My responsibility was to
audit/troubleshoot the distribution implementation and to re-configure the Purchasing
and Inventory modules, menus, versions and AAIs. Key issues included managing data integrity
and helping the users understand how the system works. Was also tasked to review accounts payable
and the impact of landed cost.
US Motors (World 7.3)
July 00 to October 00
A subsidiary of Emerson Electric, US Motors manufactures electric motors and has three manufacturing locations in Monterey Mexico, Arkansas and Mississippi. My primary responsibility was to act as Sr. Consultant in implementing the Manufacturing Modules at the Monterey facility including Product Costing, Manufacturing Accounting, Manufacturing planning (multi-plant) (MRP), Shop Floor Control, Engineering Change Management and Product Data Management. Tasks included configuring all AAIs, Menus, Versions and creating reports. Key issues included the accounting ramifications of transferring material in and out of a maquela dora using the ST/OT process.
Chromalloy (World 7.3)
February 00 to July 00
Chromalloy’s Kelly Air Force Base facility is contracted to repair and re-build jet engines for the US Air Force. My responsibility was to act as Sr. Consultant in implementing all the distribution modules and a portion of manufacturing including, Sales, Purchasing, Forecasting and Inventory. Tasks included configuring all AAIs, Menus, Versions, designing/executing all CRP and test scripts and creating reports. Key issues included approval processes for requisitions, planning for replacement parts requirements, satellite storage facilities and electronic data interchange for sales.
Bayco (World 7.3)
July 99 to October 99
Bayco is a $30 million electrical appliance company Located in Dallas, Texas with a sister plant in Mexico. My responsibility was to act as Sr. Consultant in implementing the Manufacturing and Distribution modules including: Forecasting, Multi-Plant Manufacturing Planning (MRP), Shop Floor Control, Product Data Management, Product Costing, Manufacturing Accounting, Sales Order Management, Purchase Order Management and Inventory Management. Tasks included configuring all AAIs, Menus, Versions, creating reports, creating/executing all test scripts including functional testing at the program level CRP.
CCP (World 7.3)
March
97 to September 97
CCP is a $300 million chemical manufacturing division of Total. My responsibility was to act as Sr. Consultant in implementing the Manufacturing modules and a portion of Distribution including: Forecasting, Manufacturing Planning (MRP), Shop Floor Control, Product Data Management, Product Costing, Manufacturing Accounting and Inventory. Tasks included configuring all AAIs, Menus, Versions, creating reports and test scripts for functional as well as go live preparation. I was also responsible for analyzing and developing specifications for any modifications that affected my area of responsibility.
International Trading
Company (ITC) (World 7.3)
January 96 to June 96
ITC is a $300 million manufacturer of meat products located in Houston, Texas. My responsibility was to act as Sr. Consultant in implementing the Manufacturing and Distribution modules including: Forecasting, Manufacturing Planning (MRP), Shop Floor Control, Product Data Management, Product Costing, Manufacturing Accounting, Sales Order Management, Advanced Pricing, Purchase Order Management and Inventory Management. As the only consultant on the project, my tasks included configuring all AAIs, Menus and Versions as well as creating/designing all reports. Additionally, I was responsible for creating/executing all functional and CRP testing scripts and go live preparation.
Gateway 2000
May 95 to November 95 (World 6.2 & Enterprise One)
Gateway 2000 is a large
manufacturer of personal computers located in Sioux City, South Dakota with
sister plants and distribution facilities located around the world. My
responsibility was to act as Sr. Consultant in implementing the Manufacturing modules and a portion of
Distribution, developing/executing all test/CRP scripts and executing go live
activities. In addition the system was
to be highly modified. I was also
responsible for analyzing and developing specifications for modifications that
affected my area of responsibility. The
system was configured and tested in Sioux City and then deployed to Japan and
Malaysia. Modules included: Configurator, Product Data Management, Forecasting, Manufacturing Planning (MRP), Shop Floor
Control, Product Costing, Manufacturing Accounting, Inventory and
Shipping. Tasks
included configuring all AAIs, Menus, Versions and creating reports.
Other Implementations
include:
Robert Mondavi (World 7.3) Wine Multi-Plant MRP and Custom Purchasing Class
Keeney (One World 7.3) Plumbing
Supplies Go-Live Audit and Manufacturing Accounting
Toshiba (One
World 7.322) Electronics Distribution
Showa (One World 7.322) Automotive Manufacturing
Poly Plastics
(OneWorld 7.322) Chemical Manufacturing
Menasco (World 7.3) Aviation Manufacturing
Kawneer (World 7.3) Building Materials Manufacturing
Houston Bay Towing (World 6.2) Manufacturing
Kvarner (World 6.2) Distribution
Texas Department of Corrections
(World 6.2) Manufacturing and Distribution
Industry Experience
09/69- 05/94
Affiliations:
APICS - Sub-committee Chairman quality and information systems Constraints Management SIG 1995, Member Constraints Management SIG committee responsible for quality and information systems 1996, Member TOC certification development team 1997.
Certifications:
·
CPIM
· Jonah and Information Systems Associate - Goldratt Institute
· Commercial Pilot – Helicopter Turbine and Fixed wing SEL
Authored Publications:
The Next Phase of Total Quality Management, Marcel
Dekker, 1993
Re-engineering the Manufacturing System, Marcel
Dekker, 1996
The Theory of Constraints: Applications in Quality
and Manufacturing, Marcel Dekker, 1997
Re-Engineering The Manufacturing System (Second
Edition), Marcel Dekker, 2003
Endorsement:
"Re-Engineering
The Manufacturing System: Applying the Theory of Constraints” by Bob Stein is
no book for the novice. Brilliantly conceived and executed it is written for
experts in the field of manufacturing by an expert". Dr. Eli Goldratt
MA,
St. Louis, MO
Chaminade University
BGS,
Honolulu, HI