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If It Moves, Scan It! The Sugar Foods Story

If It Moves, Scan It! The Sugar Foods Story. Kerry White, Sugar Foods Ray Agrusti, Eagle Global Services. #1 Supplier of sugar substitutes. SUGAR FOODS PRODUCTS ARE CONSUMED 80 MILLION TIMES PER DAY!. #1 Supplier of almonds. #1 Supplier of croutons and crunchy salad toppings.

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If It Moves, Scan It! The Sugar Foods Story

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  1. If It Moves, Scan It!The Sugar Foods Story Kerry White, Sugar FoodsRay Agrusti, Eagle Global Services

  2. #1 Supplier of sugar substitutes SUGAR FOODS PRODUCTS ARE CONSUMED80 MILLION TIMES PER DAY! #1 Supplier of almonds #1 Supplier of croutons and crunchy salad toppings #1 Supplier of powdered, non-dairy creamer

  3. Commercial Food Service Providers Retail and Consumer Non-Commercial Food Service Providers Warehouse clubs Supermarkets Mass merchandisers Restaurants Hotels Colleges Health Care Facilities SUGAR FOODS PRODUCTS ARE DISTRIBUTED TO MORE THAN 850,000 OPERATORS

  4. Takes sales orders; Produces dry items, condiment type Bakery items Bakery and dry items • Sugar Foods operates four manufacturing facilities, with another coming on-line later in 2008.

  5. Manufacturing Manufacturing in 4 Locations: Sun Valley, CA Villa Rica, GA Commerce, CA Mazatlan, Mexico Service the following markets: Foodservice Specialty Markets Office Coffee Services (OCS) Vending Convenience Stores Membership Warehouse Clubs Retail Mexico and Beyond! Villa Rica, GA (340,000 sq ft.) (10 football fields) Sun Valley, CA (180,000 sq. ft.) (5 football fields) Commerce, CA (250,000 sq. ft.) (7 football fields) Mazatlan, Mexico (70,000 sq. ft.) (1.5 football fields)

  6. Challenges • Less than acceptable inventory accuracy • Maximize efficiency and profitability • Limited granularity in transaction history • Unidentifiable products with similar characteristics • Meet compliance requirements for lot traceability • Position for future growth

  7. Meeting the Challenges: Phase 1 • Implemented QAD Eb2.1in 2006 • QAD recognized Sugar Foods with its “Rapid Implementation Award” at Explore 2007 • Discovery to GO-LIVE in 77 days

  8. Known Challenges – Specific to ADC • Inventory accuracy or a single location called “OT” • Inventory that’s “Out There” somewhere • Real-time information • Elimination of manual logging of raw materials • Track materials from receiving through production and then shipping by means of an automated system that provides full lot traceability

  9. Sugar Foods chose Eagle’s RF Express™ for QAD Enterprise Applications The Right Solution for Sugar Foods • Chose Intermec Corporation’s CK31 RF handheld devices • Chose Zebra Technologies 105SL bar code label printers for the shop floor

  10. Why Eagle? • Strategic QAD Partner since 1992 • Seamless integration with QAD EA • Progress-based solution • 99% data accuracy or better • Real-time data capture without changes to QAD code • Personal experience with Eagle’s solution • Ease of implementation and use • Hardware and device flexibility

  11. Phase 2: Leveraging QAD EAwith an Automated Data Collection Solution “ERP system implementations have 50% higher benefits when integrated with an Automated Data Collection System.” Gartner Group 2001 • Began ADC of raw material data in Villa Rica facility in July 2007 • Receiving • Material transfer • WIP production • Completed rollout of raw material in Sun Valley in September 2007 • Completed rollout of raw material in Commerce in December 2007

  12. HOW DID WE DO IT? • Made early determination that all items should be tracked utilizing pallet ID’s with very few exceptions • Identified data that should be visible and scanable on all items (Label Definitions) • Identified material flow and drop-off/storage locations • Identified QAD transactions required to achieve maximum efficiency and traceability • Identified Eagle transactions • Labeled all possible storage locations (racks, floor, trailers, etc.) • Performed repetitious hands-on training with users

  13. CAN WE SEE UNDER THE HOOD?

  14. KEYS TO SUCCESS? • “Know the Flow” • Simplify the process • Provide as many tools as necessary • Reduce keypad entry • Review the process periodically

  15. Where do we go from here? • Implement scanning of finished goods w/lot control • Production recording using backflush transaction • Pallet transfer between inventory locations • Sales order picking & shipping • Meet specialized customer labeling requirements • UCC/EAN 128 labeling • RFID labeling • Link to ASN transaction • Inter-company transfers utilizing DRP • Implement all scanning functionality in Mazatlan facility • Turn on lot control for raw materials

  16. Kerry White IT Manager, Villa Rica Facility Sugar Foods Corporation +1.770.459.5225 +1.770.459.9863 (fax) KWhite@SugarFoods.com www.SugarFoods.com Contact Information Ray Agrusti Senior Product Consultant / Project Manager Eagle Global Services +1.973.838.5006 +1.973.492.2758 (fax) RAgrusti@EagleConDev.com www.EagleConDev.com RF Express™ for QAD Enterprise Applications is a trademark ofEagle Consulting and Development.“QAD” is a registered trademark of QAD Inc. All other products or Company names herein may be trademarks of their respective owners.

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