Effective packaging-related specification management software for a packaging documentation system

Rochester Institute of Technology

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2003

Effective packaging-related specification

management software for a packaging

documentation system

Gregory Cullen

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Recommended Citation

Effective Packaging-Related

Specification Management Software for

a Packaging Documentation System

by

Gregory M. Cullen

A Thesis

Submitted to the

Department of Packaging Science

College of Applied Science and Technology

In partial fulfillment of the requirements for the degree of

Master of Science

Rochester Institute of Technology

Department of Packaging Science

College of Applied Science and Technology

Rochester Institute of Technology

Rochester, New York

CERTIFICATE OF APPROVAL

M.S. DEGREE THESIS

The M.S. degree thesis of Gregory M. Cullen

has been examined and approved

by the thesis committee as satisfactory

for the requirements for the

Master of Science Degree

Craig Densmore

Duane Beck

Illegible Signature

Illegible Signature

Permission Denied

EFFECTIVE PACKAGING-RELATED

SPECIFICATION MANAGEMENT SOFTWARE FOR

A PACKAGING DOCUMENTATION SYSTEM

I,

Gregory M. Cullen, hereby deny permission to the RIT Library of the Rochester Institute of

Technology to reproduce my thesis

in

whole or in part.

Acknowledgements

Thanksare dueto Scott Stewartfor_{reviewing my}thesisand_allowingmeto dothesisworkat

Duracell;

manufacturingaffiliates who filledout_{myquestionnaire;}Victor Calcerano for

reviewing

beginning

sections of_mythesis; Pam Cullenfor

being

_mytechnicaleditor;andDawn

Dedication

EFFECTIVEPACKAGING-RELATED

SPECIFICATIONMANAGEMENT SOFTWARE FOR

APACKAGING DOCUMENTATION SYSTEM

By

Gregory

M. Cullen

Abstract

Anextreme amount oftimeand_{money is}lostwhen a_companyutilizesaninadequate

packaging documentationsystem. Problemssuchas_confusion, decreased_{productivity,} inaccurate

information,

andinefficienttime tomarket arise.

Having

therighttool (inthiscase

specific_{software) for}thejobwill_successfullyprovide neededinformationto flowthroughouta

packaging documentationsystem. In

investigating

theimportanceofthis_tool, Duracellwillbe the_companyfocusedonas partofthiscasestudy.

Duracell'

s current _{packaging documentation}

system consistsofa series ofinternalelectronictransfersandphysicaldistributionof_packaging

specifications. Relevantinformationisdistributed among departments insidethe_companyand

otherdepartments/affiliated businessesoutside ofthe company.

Duracell,

aswellas_manyother

companies,can cut significant costs

by

_{effectivelymanaging information}and

having

well-organized_{proficiently operating}specification managementsoftware. Thepurpose ofthis_study

isto compare, evaluate, anddetermineDuracell's current_{packaging documentation}management

needs. After exarriining DCS (Document Control

System)

6.0

Professional,

itwasfoundtobe a

muchmore effective softwarethanDuracell'scurrentDCSsoftware _system,DCS 2000. The

hypothesisofthisparticular_{study is}thatallthetypesof_{Duracell's packaging documentation}

(artwork,

billof_materials, CAD

drawings,

pallet_{patterns,planograms, etc.)}canbe integrated

intoDCS 6.0

Professional,

which canoffera greatdealof costandtime savingsthroughout Duracell's packaging documentationsystem. The study determinesthatDCS 6.0

Professional,

when_{properlyused,} can provideDuracellwithabusiness solutionthatenables successful

management functionsforcompleted_{packaging documentation}to occurthroughDuracell's

ListofTables

Page

Table 1. Automatic

Packaging

Specifications System Checklist 26

Table2. Ten NeededSoftwareorManagementFunctions 28

ListofFigures

Page

Figure 1. Anupgrade proposalprice _{for DCS 6.0 Pro} 39

Figure2. Duracell'scostforDCS 2000 40

Figure 3. DCS 6.0 Pro User Controls 44

Table ofContents

1. INTRODUCTION TO

DURACELL'

S PACKAGING SPECIFICATION SOFTWARE

ANDPACKAGING DATAMANAGEMENT PROCESSES 1

1.1. Internal ProblemsandCauses withDCS 2000andManagement 1

1.2. External ProblemsandCauseswithDCS 2000andManagement 6

1.3.

Packaging

Industry's Material CostsandBenefitsofWeb-Based

Technology

1 1

1.4. Hypothesis 13

2. PACKAGINGSPECIFICATIONMANAGEMENT SOFTWARE TECHNOLOGY 14

2.1. An Outlookon

Currently

Developed Software intheMarketplace 14

2.2. Global

PKG,

Inc 15

2.3. Mountain

Systems,

Inc 16

2.4. Mystic Management

Systems,

Inc 18

2.5.

Paxonix 19

2.6.

Sky Technology

Partners,

LLC 21

2.7. Reasons for

Staying

withMystic'sSoftware 22

3.

THE IDEAL SYSTEM FOR DURACELL'S PACKAGING SPECIFICATION

MANAGEMENT SYSTEM 24

3.1. Process Flowof

Packaging

Documentation/Project Information 24

3.2. NeededSoftwareorManagement Functions 26

3.3.

Avoiding

Obstacles 32

4. EVALUATION OF THE DCS 6.0 PRO SYSTEM 34

4.1. ConditionsofEvaluation 34

5. RESULTS 42

5.1. PerspectiveofProcesses Analyzed 42

5.2. Perspectiveof_{Deliverables Neededfor DCS 6.0 Pro 51}

5.3. PerspectiveofCostand

Rating

ofDCS6.0Pro 53

6. CONCLUSIONS 56

6.1. Conclusions 56

6.2. FutureConsiderations 57

Works Cited 58

Appendix A: TypesofDuracell's

Packaging

Documents 60

Appendix B: ViewsofBOM InformationwithinDCS 2000 63

Appendix C: Questionnaire 80

Appendix D: Viewof anOld BOM Hard

Copy

81

Appendix E: Duracell's

Packaging

Department's Flowcharts 82

Appendix F: ViewsofNeeded Functionsin DCS 6.0 Pro 84

Appendix G: ViewofCurrent BOM Hard Copies 90

1.

INTRODUCTIONTO

DURACELL'S PACKAGING

_{SPECIFICATIONSOFTWARE}

AND PACKAGING DATA

MANAGEMENT

PROCESSES

1.1. Internal Problemsand Causeswith DCS2000 _andManagement

In

May

1999,

_{Duracell's packaging departmenthadbecometheprimaryuserforits}

packagingspecification management software

-Document Control System

(DCS)

2000- _within

the

Bethel,

CT basedHeadquarters. Thisspecification software developed

by

Mystic

Management

Systems,

Inc. hasshortcomingsfor

developing

an effective_packaging

documentationsystem, which_negativelyeffects internal/externalmanagement.

As a_result, DCS2000 _{limits Duracell's packaging} datamanagement processes

by

not

effectively guidingthedocumentlifecycle intermsof workflow. _{Duracell's packaging}

departmentdoesnotfunctionas_successfullyasit_could, sinceDCS 2000 is

lacking

inweb-based

technology

thatwas utilized yearsbeforetheinstallationofDCS 2000.

Additionally,

itwas

never

thoroughly

analyzedforitseffectivenessin providing informationto_{manufacturing}

affiliates.

Themajor problemwithDCS 2000 isthatit doesnot savetime. Thisaffectshow

managementfollowsproceduresfor packaging documentationguidelines. Thesoftware

technology

doesnot

help

create a sufficient amount ofdocumentapproval/distributiontimeand

effectivenessfor packagingengineers. Technologicalsupportcannotbe sufficientlyprovidedfor

DCS2000rnalfunctionsdueto thenumberoferrorsthatoccur

during

use. Thisis becausethe

platform(MicrosoftVisual

FoxPro)

DCS 2000wascreated uponprovides limitedcapabilities.

Theinterface itwas createduponisalso notalways_{user-friendly in}the_wayit is_organized, and

computer glitches onitoccurfrequently.

Morning

updates(automatic back_upof_work)and

negativelyimpactstherapidturn around of projects. Ifittakes the_{packaging department longer}

to do its

job,

thenittakesotherDuracellinternal departmentsandDuracell'soff-site

manufacturing affiliateslongerto dotheirjobas well. _{This ultimately}hasanegativeimpacton

the

delivery

_{time to market,} which_{is extremely importantin}such a competitive industry.

The packagingdepartment'sgeneraldocumentationneeds are togenerate andmanage

material specificationdocuments

(artwork,

billof_materials, CAD

drawings,

_supportingtext

documents,

etc.). Thiscanbeaccomplished via a rapid and effective processforall new product

launchesand_ongoingproduct modifications. Thisspecificationinformationisvitalfor batteries

tobepackaged ontimeinordertomeetthevarious production and shipmentdeadlines. The

majorityof a_packaging engineer's workload should notbefocusedon

having

to followa

long

inefficientprocesswhen_creatingor_revisingdocuments andthen_approvingthemone

by

one.

Thefocusshould_{be spending}moretimeon cost _savings,new_products, and_productivity

improvementprograms.

DCS 2000 isa personal computer-basedprogramand adatabasethat _specifically

addresses documentationfor packagingcomponentandmaterialspecifications. Theplatformfor

thedatabase used

by

DCS

2000,

Microsoft Visual

FoxPro,

containsdatafieldsofitemcodes or

part numbersfor manydocumenttypes thatcansometimes makeit confusing fortheaverage

userto decidewhatdocumenttypes touse. Appendix Aisalist

describing

allofDuracell's

packagingdocumentationtypes. Forexample,acertaintypeofdocument canbe foundunder

severaldocumenttypes. Some documenttypesareimported intotheDCS 2000templatesand

others are created withinDCS2000templates. Documentscanbecreated with other

manyothers(MysticHome Page 1). In_essence, DCS 2000resemblesamulti-userenvironment

putinto a single system.

Therearefourmaintypesof_{packaging documentation}atDuracell in DCS 2000:

drawing

specifications, billof materials

(BOMs),

graphic_{specifications,}andpalletpatterns.

Drawing

specifications useAutoCAD (AutomatedComputer Aided

Drafting/Design)

2000 software. A

user(Duracell

draftsman)

developsallof_{Duracell's packaging}component drawings. Adobe

Acrobat softwareisusedtocreate

drawing

files ina publisheddocumentformatsothat drawings

canbe imported intoDCS 2000. In DCS

2000,

users(Duracell packagingengineersand

document coordinators)create BOMswithintemplates inthedatabase/software. Graphic

specifications are produced

by

Duracellvendorsontheirown_software,such asAdobe

Illustrator. Theartworkdocumentends_up

being

ina publisheddocument format inorderforthe

user(Duracellgraphic_coordinator) toimport _anyartworkinto DCS 2000. Palletpatterns are

developed in CAPE softwarethat theusers_{(Duracell packaging engineers)}

develop

forallthe

patterns. Thepallet patternsarethenconvertedintoa publisheddocument formatsothat_any

pallet pattern canbe importedintoDCS 2000.

The BOMistheformula forallkindsof

battery

_packagingcomponents

(primary

packaging, secondarypackaging,

tertiary

packaging,etc.)thatcometogether inaproper

sequence and_{quantity for}completionofthepackaged product.

Many

differenttypesof

packaging documentationcan go into it alongwith_anyother significant relateddocumentation

thatneedstobeincluded. In Appendix

B,

views ofBOM informationwithinDCS 2000 are

givento illustratewhat_maygointoaBOM. SincetheBOMisalistof_packagingcomponents

and related

documents,

it is importanttorememberthatawell-structuredBOMcan_simplify

10). Anin-depthanalysisof_reoccurringissueswithBOMs isstudied more inthe

following

sectionofthischapter.

Managementproblems with workflow reflect an

inconsistency

of

terminology

thatoccurs

with_{DCS 2000. The way}one_packagingengineerdescribesa component_maynotbe how

another_packagingengineerdoessoin DCS 2000. Thiscan create_{misunderstanding}or

confusionwhen_searching for documentsorwhen_{manufacturing}affiliatesreceivehard copies of

BOMs. Otherproblems arethat

(a)

sometimesdocumentsare missedordropped fromtheonce a

weekdistributionofdocumentsto _{manufacturing} affiliatesor

(b)

they

end_upgoingoutto the

wrong manufacturingaffiliates. Alloftheseproblems_maycause_packaging componentwaste

becauseproducts are madeto the_wrongor an outdated specification. BOMinformationmight

notbeprovided_correctlyto aDuracell planningforce ina

timely

manner.

Internally,

planning demandmanagement needstohavepart_numbers,component

quantities,and other relevant _packagingspecificationinformation fromthe_{packaging BOM.}

Sometimesincorrect mformationiscopiedfromtheBOM_{into supply}chain management's

software, Enterprise Resource

Pjlanning (ERP)

system calledJ.D. Edwards

(JDE)

by

theuser.

Thiscreatesineffectivecommunicationbetweenthe two systems. Employeeshavea certain

degreeof_{accountability}when_{copying information}fromone systemtoanother.

However,

there

isavailable

technology

thatcouldbe utilized forsuchamajor_companyasDuracell. Thecost of

this

technology

wouldbebalanced

by

increasedprocess effectiveness. DCS2000 andJDE

software shouldbetwo systemsthatcanbeintegratedtogether

by having

a programmed

interfacebetweenthem. Itis hardto measure or put a price

tag

onthebenefitsoftechnological

improvements,

but

by decreasing

thechances of

having

incorrect informationsent outfor

employeesatisfaction. Thetime savedcouldbe spent on_{reducing operating}costsand_gaining

1

.2. External Problemsand Causeswith DCS 2000 _and Management

SomeofDuracell's manufacturing operationswill sometimes produce_upto 200 different

Stock

Keeping

Units

(SKUs)

each month and average a 15-linechangeoverdaily. Each SKU

averages about6component parts. It_{is absolutely} criticalto Duracell'soperationto havethe

correct parts ontheproductionline.

Packaging

data haveacrucial role

by

_gettingthecorrect

informationinorderfor ittobeproduced andtonothave waste occur.

Aquestionnaire(appendix

C)

was giventoDuracellaffiliatesthatare involvedwiththe

packagingdata inordertodeterminetheexternal problems of_{Duracell's packaging}

documentation.

In 18of29responses, a_majorityofnegative responses came_{from manufacturing}plants

(internal manufacturingand contract packaging). Theseare_veryimportantacknowledgements,

sinceDuracell's manufacturingplantsuse allthedocumenttypes_packagingengineers

develop

at

the

Bethel,

CT-basedheadquarters. Thehard_copyoftheBOM's layout is_problematic, because

thedesignofthelayout isdifficultforinternal/externalaffiliatesto understand.

Thus,

theuseof

anykindof specification management softwarewillincreaseprocess effectiveness.

Ofallthe_packaging documents listedas"ineffective"in_{the questionnaire, the}BOMwas

listedmost often as"ineffective." Thismeans documentation issuesoccurredformost ofthe

documents listed. BOMsat most ofDuracell's manufacturing divisionsare _verydifficult forthe

userto understand. Interpretationisdifficult_{for manufacturing} employees who needtouse

BOMs. Their understandingisthat theBOMsreplacedthe_packagingcharts(theold style

BOM),

which provided users moreinformationtopackagetheproduct. TheBOMsare more

confusingand often_wrongor appeartobe wrong. Itwas mucheasiertoread andinterpretthe

page. Quantitiesperitemwere_easyto read and straightforward. The "oldstyle"

packaging

chartslisteditems in_{packing order,not numerical order. The}currentBOMrequires

manufacturingto calculate somethingsneeded forthem to

develop

theUPC barcode labelsthat

go oninnerand outer cartons.

Manufacturing

doesnot receive artworkina

timely

_manner,and

they

haveevenhadto request copiesattimes. WheninaccurateBOMsare

issued,

manufacturing hasto request updatedBOMs inordertomeet ISOcompliance.

They

_mayalso

receiveartworkthatdoesnot pertainto thecorrect_{manufacturing}plantand will_usuallyget

eitherthedrawingsor_{the artwork;}

hardly

do

they

ever receiveboththedrawingsandartwork

together. Thedrawings themselvesareeffective,buttheissue isthe timelinesswith which

they

receivethem.

Furthermore,

product arrives onthedockwithout_anycolor standards and without

an update ofthe measurable print.

A confusing

terminology

problemexistsintheBOMand

Packaging

Change Notification

(PCN)

documents.

Manufacturing

hasnoticed

terminology

issues. Inner_cartons, shipper

cartons,

display

cartons, and_stampingrequirements canbeconfusing. BOMsdonot use

commonlyreferredto terms that_{manufacturing}uses.

Having

alltherelateddocumentslisted is

also confusing. Whatwouldbemorehelpful isa clearsegregation of actualitemsusedtobuild

theproduct

(BOM),

_alongwiththerelateddocuments. At_times,two revisionsforthesame

drawing

appear onaBOM. Therevision atthe

top

appearstobeatwo-digitnumberwiththe "0"

alwaysto the side ofthe actualrevision number. Forexample,2 0wouldbe shown ratherthan2.

Someonenot_veryfamiliarwiththeBOMprocesswould mistakethatas a revision20. Often

PCNswillhave_{non-manufacturing}plantitemsonthem. Whatisneededisa codethatwilltell

manufacturing ifanitemisfortheirparticular_{manufacturing}plant. Thiswould savetime

informationnot relevantto that_{manufacturing}plant. Throughout

Duracell,

all affiliatesneed to

strivefor_consistencyof

terminology

andinsurethatallinvolvedunderstand_whycertain part

numbers are assigned

(i.e.,

custom promotional components part numbersvs. _packaging

component part numbers).

The flowand configuration ofinformationto_{manufacturing} is doneinanunorganized

way. Thebiggest information flowproblem_{manufacturing} seesis

timing

inconsistency

with

regardstoJ.D. Edwards

(JDE)

software,whichisnotaDCS 2000function. Itisnotuncommon

tohave demandforproduct without

having

the

BOM,

_artwork,or otherdocumenttypes. There

are also times thatnew artworkissent, butmaterial cannotbeordered, because JDE setupisnot

complete.

Packaging

documentation itemsonBOMsareinnumerical_order,not

by

sequence of

packagingevents as onthe"oldstyle"

BOM (appendix D). Items listed insequenceofevents

wouldbemorehelpful.

Theartwork and

drawing

documentsstillcomeinat odd_times, not alltogetheras

requested. Onewithouttheotherisnoteffective. PCNs do not always come

first,

and

sometimes_{manufacturing is}not sure_why

they

are_gettingtherevisions/duplicate copies. At

times

they

receivePCNsanddonotknowwhatfinishedgoods are_affected,anddo not receive

revisedBOMsatthe timea partnumberisrevised.

Consistency

withtheartworktransmittal

letterneedstobe developed

by having

theletterstate whatit is replacingorifitisnew. Itwould

bea goodideato referencetheapplicable PCN.

An_{important manufacturing}viewisthat theoverall_packagingdocumentationwouldbe

better deliveredif itused an electronicmedia ratherthanpaper(hard_copy), since

they

donot

yousee specificationinformation_online, wasdeterminedto bea neededfeature as

long

as itwas

configured anddesignedtherightway. Automatic approval, automaticnotification,andrevision

history including

current and olddrawingsshouldbe

key

featuresforthisprogramfor

appropriate usersto getthe applicable_packagingspecificationsinformation.

ADuracell_{manufacturing}representative suggestedthe_{packaging department have} a

team_{formed consisting}of membersfromallusersofthe system. Plantrepresentationfromall

theplants shouldbeonthis team.

According

to the representative,a web-based systemshouldallowthe

following

characteristics:

printing oftruecolorsforartwork.

automatic

Packaging

Change Request

(PCR)

approval,

including

manufacturing

locationsthat are_affected, evenifgeneratedin Bethel

Packaging

Engineering.

automaticapprovalinorderto allowfor designeestoapproveintheabsence ofthe

approver.

user-friendly system,especiallywithrespect toaccessto and_viewingof_prints,

layouts,

artwork, etc.that a

battery

packercould use. (Anonymous

1)

Manufacturing

and

Quality

associateswouldliketo go on-line

directly

fromthe

manufacturing floor. Thiswouldenablethem to searchonthespecificitem

they

need(i.e. pallet

configuration,assembly

drawings,

etc.)without

having

to cometo theoffice area and gothrough

file drawersorbooksofhundredsofdocumentstofindtheoneitem

they

need.

Ingeneral,aweb-based program wouldbe ofgreatbenefitto all. Sucha program would

ensurethateveryoneis_workingwiththemostcurrent revision. Itwould eliminate hard_copy

Duracell qualityassurance managerbest describes howthe _set-upof BOM'

sshouldbe

considered:

When

designing

theDCS

layout,

keep

theinternal andexternal usersinmind.

Further,

themanager_says, Considertheuser. Whatthe_packagingengineer wantsto seeisnotthe

same aswhatthe_{manufacturing}supervisor or_qualityauditor wantsto see. Givethem

what

they

need todo an effectivejob.

Manufacturing

wantsconciseinformationwithout

1.3.

Packaging

Industry's Material Costs_andBenefits _ofWeb-Based

Technology

Virtually

everycompanyneedsto have itsproducts shippedto theend_user,andfor

Duracellit isattheretail level. Thismeansthata_majorityof companies need and usetransport

packaging.

Many

organizationsdo nothavean_{understanding}ofthe cost _savingopportunities

possible with respectto theredesign oftransportpackaging.

Robert FiedlerandDouglas Tenpaspresentedthe

following

informationatthe2001

InternationalConferenceonTransportPackaging:

Thetransport _packagingmarketis_growingat a rapid rate. Themarketfortheseproducts

amountedto

$30,000,000,000

inmaterial costsin 1997. Theoverall_packagingmaterial

costsforthe transport_packagingmarket intheUnitedStates

industry

wasprojectedto be

$40,000,000,000

by

theendof2001. Theentire

packaging

industry

willspendan

estimated$1_{15,000,000,000 in packaging}materials

by

2001,

andthe totalworldwide

estimateisover

$300,000,000,000.

Furthermore,

theimpactsof_{distribution packaging}

methods extendwellbeyondthedirectcosts. Theeffects on product_quality, distribution

expense,lineanddistribution throughput, and communication performance

typically

dwarfsthematerial expense.

(2)

Thisis_{why it} isimportantto havea_{packaging documentation}systemthatincorporatesan

effectivedataandcontentmanagement solution.

By

_{this means, the} appropriate

information

can

getto the right userinaWeb format. Aweb-based programis a cost-effective systemthatcan

assistin

decision-making

andimprove_supplychainmanagement.

Awelldocumentedandorganizedeffortto _{improve packaging} designsand

implementation_process,combinedwitha realweb-baseddocumentationmanagement_system,

reductioninthecosts ofpackaging, theorganization will also improvematerial

handling,

reduce

transportationcosts,reduce

inventory,

reduce warehousespace,reducedamage dueto

1.4. Hypothesis

DCS 6.0 Pro is packagingspecification management softwarethatcanoffera great deal

ofcostandtime savingsthroughout_{Duracell's packaging documentation}management system.

Totestthis

hypothesis,

two typesof packaging-related specificationmanagement

softwaresystems were subjectedto dataanalysis. Duracell'ssoftware systemiscalledDCS

(DocumentControl

System)

2000. The new

technology

analyzedin_{this study,}DCS 6.0

Pro,

shouldbea replacement product or upgradefor Duracell's packaging department. After

Duracell'sdatamanagement needswere_{established, the}dataanalysiswasperformedunder an

operatorconditioned computer environmentinordertocomplete an evaluationfor DCS 6.0 Pro.

Bothtypes ofdevelopedsoftware systemslead upto_producing theBillofMaterials

(BOMs),

whichwill

display

allthe_packagingcomponentsfor

building

thepackagedproduct.

Comparisonsweremadebetween DCS 2000'sandDCS 6.0 Pro'send resultswith respectto

how effectively

they

produce_packagingspecificationdocumentsthat go intotheBOM

2. PACKAGING SPECIFICATION

MANAGEMENT

SOFTWARE TECHNOLOGY

2.1. An Outlookon

Currently

_{Developed Softwarein the} Marketplace

Inthe_packaging

industry,

fewcompanies exist forthedevelopmentof_packaging

specification management software. In_{this study,}Global

PKG, Inc.,

Mountain

Systems, Inc.,

Mystic Management

Systems, Inc., Paxonix,

and

Sky Technology

Partner,

LLC arethe_only

companiesfoundto offer complete offtheshelf packaging-related softwaremanagement

systems. Mostofthese companies areintheprocess of_updatingor

developing

new software

systemsinordertomeet_packagingdocumentationand_supplychain management needs. It is

expectedthatmost ofthesecompanies willhavethese systemsdevelopedwithina year.

Eachtypeof softwarethesecompanieshaveproducedorareintheprocess of_producing

hassome significantdifferences ininternal functions. Somecurrent versionsare

lacking

inareas

of_{securityaccess,} versioncontrol, and inthe_{dynamic updating}ofdata. Theexternalfunctions

thatbuilda web environmentfor packaging documentationare atrue_{differentiator among}

packaging-related software companies. Companiesthatdealwith_{packaging documentation}and

purchase software with aweb-based programare_realizingthat

they

can_effectivelyusethis

technology

toexchangecriticalbusiness information inareal-time webenvironment.

They

are

bringing

productsto marketfasterand at alowercostthan theircompetition.

A packagingengineer'sbestalternativefor solvingcomplex problems_{may be}ateamof

resources and contactsthat canbe drawntogetherand communicaterealtimeonaweb-based

program. Today's e-commercetools are_providingsolutionstorevitalizethe_packaging

engineer's_position, as well as_{providing instant}resourcesandthe_abilityto

develop

and maintain

2.2. Global

PKG,

Inc.

TheGlobalPKG websitestates

GlobalPKG

_isthe_onlycomprehensiveweb-based solution

forthefragmented_packaging

industry

today.

(GlobalPKG)

_{While GlobalPKG may be}

comprehensive, thisisnot _exactlyatruestatement sincetheother companies_{previously listed}

either_{already have}a web-based solution orwillsoonbe comingoutwith one.

GlobalPKGisa_relativelynew_companythathasaproductdemo onitswebsite. The

publication

Packaging

Worldreportedin April 2002that the GlobalPKG_companywasfounded

fromtwootherfailedcompanies. Afirmnamed3Comstreamlined packagedesignthroughthe

useof an application service provider called

WebPkg

.

Meanwhile,

Proctor& Gamblestarted

someinvolvementwith an online solutions_provider,Packtion (Reynolds).

However,

both

Packtionand

WebPkg

have gone outof

business,

andthe_{latter company is}saidto_{be resurfacing}

at www.gpkg.com.

GlobalPKGmentions onitswebsitethatit iscommittedto theideathata product-centric

approachtoward_packagingsolutionscanaddresstheenormousimpactthat_{packaging has}onthe

totalcost of product and reveal

intriguing

opportunitiesto enhance competitive advantage

2.3. Mountain

Systems,

Inc.

Mountain

Systems,

Inc.

(MSI)

isa

leading

application softwaredevelopment_company

forthe_{manufacturing}industries. In

1999,

Sarbrook

Company,

Inc. was acquired

by

Mountain

Systems,

Inc. and addedthesoftwareWinSpexto_{Mountain Systems}Inc.'sline of products and

services. Sarbrook

Company,

Inc. was foundedin 1990to offer

fully

integrated software

systemstomeetits

clients'

manufacturinginformationcontrol needs. Thegoal: tomaximizea

company's management anddistributionof

information,

thereby

increasing

_{their efficiency,}

performance, and_{profitability (Sarbrook).}

Thoughtheproduct promises greatresults,MSI hasdecidedtophase out WinSpex

by

fall

2003 inorderto introducea new product.

Thus,

itwould notbeworthwhiletoincorporate

WinSpexinthenearterm. The softwaredevelopment_{company IntellaPac is}

taking

over allof

WinSpexbusiness_{applications,} buttechnicalsupportis limited.

Oneofthe advantages of_{using WinSpex}was_{increased accuracy in}theirsoftware

by

_way

of standardized specification

formats,

whichreducesthechanceof errors and/orduplication.

Security

has strict control over access andapprovals, and accessto eachdatafieldcanbe

individually

controlled. Afullaudit

history

is_{automatically}recordedfor monitoring and_quality

compliance.

Another

key

objective ofthisand other softwarespecifications systemsis_reducingtime

tomarket. Thiscanbeachieved viashorterleadtimes forapprovalof new and revised

packagingmaterials. Enhancedcommunicationsbetween

individuals,

departments,

and

locationsresultsina more efficientworkflow. Immediatereal_time,on-line accessto

With

Winspex,

specificationssystems aredesignedto meetindividual companyneeds,

witha standardizedtemplatecreatedforeach_packagingtype. For_{example, the}systemforauser

ofplasticbottlesmightincludetemplatesfor

bottles,

_closures,

labels,

and outercases. These

2.4. MysticManagement

Systems,

Inc.

Mystic Management

Systems,

Inc.

(MMS)

wasfounded in 1984to

develop

database

solutionsforspecification and documentcontrol(MysticHome Page 2). Mysticspecializesin

applicationsfor documentchange _{control,document life}cycle_management,andwork flow

integration. Mysticisonetheearliest entrantsintothe_packagingand

Planning

Demand

Management

(PDM)

market. Thebasesoftware_system, DCS

2000,

wasdevelopedwiththeidea

toprovide a secure and structured methodfor

handling

criticalinformation_relatingtoproduct

designand associated_{manufacturing}processes. MMShadannounced plansto launchanew

DocumentControland SpecificationManagement Software SolutiononOctober

1, 2002,

named

DCS 6.0 Professional. DCS 6.0 Professional is

being

marketed as ahigh-performance document

control and specification management applicationthatprovides great

flexibility

and enterprise

collaborationthataids companies_{in controlling}theirdocumentationprocesses and_addressing

stringent_regulatoryrequirements(Mystic Home Page 1). Thisapplicationhasa web-based

2.5. Paxonix

PaxonixannouncedinDecember2000the

development

of anInternetenabled system

designedto

help

consumer product companies _{improve profitability}and globalcompetitiveness

throughnewandbetterways of_creatingand_{commercializing}packaging. Paxonixis_responding

to theneedfora moreintegratedand collaborative approachto_{packaging design}and

development.

They

are

looking

to

help

companies acceleratetheirspeedto marketfornew

product launchesand relaunches. (Paxonix Home Page

1)

Thissystem wouldbedifficultto implementat

Duracell,

since_gettingstartedbeginswith

transitioning

projects,projectteamsand assetsto thePaxonixenvironment.

Transitioning

tothis

systemwouldbe extremely difficult for Duracellor_anyother_companythat_alreadyhasasolid

foundationwith another_packaging software system.

However,

Paxonixdoesprovide a service

team_{to, among}other_things,assist with_convertinga company's product and package

developmentprocess overintothePaxonixenvironment.

Companies

joining

Paxonixcan utilizetoolsdefined

by

their levelof_monthly

subscription. Thetools,availabletoboth PC andMacusers via standardInternet

browsers,

employintuitive featuresto guideusers. Users begin

by

_{accessing Paxonix's packaging}

specification serviceto _{build packaging}andspecifications fromscratch, orelse

they

can work

from designsstoredintemplates. Artworkforacustomer'sbrandsor products can_{easily be}

retrievedfroma centralized

library

throughthedigitalassetmanagementservice. Graphicand

structural components canbeprototyped

by

_{using Paxonix's 3-D modeling}software. (Panonix

Home Page

2)

PaxonixtoolsincludeInformation

Services,

whereusers willfind: a

library

of_packaging

regulatory

information,

andbest-practiceapproaches. Alsoplanned areeducationalcourses in

packaging subjectsforpersonnel withdifferent functional backgroundsandlevelsofexperience,

aswellas

training

sessionsforPaxonixtoolsand services and_packagingequipmenttechnology. A

key

elementofPaxonixisitscollaboration_{tool set,}which allows companiesto

convene

design,

productionandprojectmanagementteamsina coordinated_working

environment. Italsoallows forrealtimeaudio andvideo _{conferencing,}aswellastask

2.6.

Sky Technology

Partners,

LLC

IntellaPac,

a_subsidiary of

Sky Technology

Partner,

_{LLC is}a softwaresolution provider

forproductand_packaging specificationmanagement solutions. IntellaPac Pro claimsto bethe

first 100%

fully

off-the-shelf, web-enabled, template-drivenspecificationmanagement system.

Its

key

feature isthatitprovides a powerfuldatabasethat serves as acentral_repositoryfor

specificationand relatedcontent. IntellaPac Proisatoolthatsupportscommunication,

collaboration, andprocessimprovementsthroughout theproductdevelopmentand

delivery

cycle. Itisa suiteof productsbuilt aroundproductand_{packagingspecifications,}

including

qualityandingredientsadd-on modules. IntellaPac providesimplementationandprocess

improvement consulting servicesto promotetheeffectiveuse ofIntellaPacProtomeet client

objectives. Thissoftwareis currently

being

developedandexpectedtobe introduced inthefirst

2.7. Reasonsfor

Staying

with Mystic's Software

After_{researchingmany}companiesthat

develop

_{packaging documentation}management

software,IhaveconcludedthatMystic Management

System,

Inc. istheright choicefor

Duracell's packagingdepartment.

Going

to another system wouldbeanexpensive andtime

intensivechange. Suchan extreme change would_onlybevaluableifthereweredramaticcost

reductioncapabilities_{in going}with another system.

Furthermore,

some ofthe companies

examineddo not_necessarilyoffer all of what

they

advertise. _{After previewing}thesoftware

demos,

Ifoundthatsome systems_{had many}control problemswithimportantdocuments.

Additionally,

stayingwiththesame _companywould

help

thetransition to thenew_technology,

DCS 6.0 Pro.

Having

Mysticconvertthe_{existing data operating in DCS 2000}toDCS 6.0 Pro

minimizesthechallenge.

Mystic's 'Upgrade ProposalofDCS 2000toDCS6.0,"

sums_upthepositiveinfluence

DCS6.0ProwouldhaveonDuracell:

DCS 6.0 Professional isa completeupgrade ofDCS 2000. Itisadocument

control systemthat takesall ofthe

functionality

fromitsprevious versions

developedover_{the years,} and migratesinto a more_widelyaccepted

technology

platform. Thissolutionwillenable

Duracell,

The Gillette

Company

in

Bethel,

Connecticutto continueto maintaina_qualityelectronicdocumentcontrol system

while

incorporating

technology

and architecturethatarethemost

flexible,

up-to-date and_widelyused. Thisupgradenot_onlygratifies users andinformation

technology

personnel,but itsopenplatformenables_easy

interfacing

with other

enterprise _{applications, that}inturnsatisfies employeesthroughout the

The

technology

changesfound in Mystic's_newlydevelopedDCS 6.0 Pro have

beenanalyzedto determine ifthesoftware can_adequatelymanageDuracell's packaging

documentationandto seeiftheupgradeto DCS 6.0 Pro isworthDuracell'stimeand

3.

THEIDEAL SYSTEM FORDURACELL'S

PACKAGING

SPECIFICATION

MANAGEMENT SYSTEM

3.1. ProcessFlowof

Packaging

Documentation/Project

Information

Inordertohaveeffective_{packaging datamanagementsoftware,}aproperflowof

information hastobe developedinan organized sequenceforeach_packagingengineer's project.

A_packagingengineer shouldbeableto _{clearly detail}thestepsthatneedto be doneto

successfullyfinisha project.

Packaging

datamanagement software shouldassist in guidingthe

flowof_{packaging information}forproper approvalinanefficientmanner. Ifthesoftwareis

effective, thenproceduresforworkshouldbe inplace. Duracellhasdonethis to someextentin

orderto standardizetheflowofinformation.

Duracell's packaging development andrevisionprocesshelps packagingengineers

by

having

themdetermine how documentation is developed fromstarttofinish. Thisprocesswas

highhghted

by

theDuracell

Packaging

Department's Flowchart (appendix

E),

whichdisplaysthe

key

stepsthatare establishedforcompletionof a project. Thefirst stepcomesfromthe

Packaging

Change Request

(PCR),

which explainstheneed_{for packaging component(s)} revision or introduction. This documentationworkisestablished

by

the

department(s)

involved inthe

packagingcomponents completion,anditneedsto_{be completely}thoroughforproper execution.

Currently,

all ofthe stepsthat follow PCRapprovalinvolve workingwithDCS 2000. The approval ofthisdocumentationisexportedinto DCS 2000 and given a codeforreference.

Projectscanbestartedwithinformationfromthe_packagingengineer andtheinformation

fromthePCR. ResearchtoolsprovidedwithinDCS2000

help

initiatethemanagement ofthe

material_options,and

terminology

haveto betakenintoconsideration. Development canleadto

moreapprovalsfornew products

by

_{evaluatingprototypes,}component _testing, and artwork.

Anexample of a_{less difficultproject,}whichdoesnotinvolvealotof steps for

completion,mightbeadatecode changeonablistercard. Nostructure changes occur.

Only

a

revisionto the textintheartwork wouldbemade. The

drawing

wouldhavea revision number

changeto

it,

and no dimensionalchanges wouldneedtobetakeninto consideration. Approvals

would needtobedone_{quickly using DCS 2000 in}orderfor documentsto bereleasedin

distributionforproductionina

timely

manner.

Duracell's packaging developmentproject process would

ideally

make_packaging

engineers pinpointwhattoconsiderwhen

dealing

witha project. Thisprocesswas created

by

theDuracell

Packaging

Department's Flow Chart (appendix

E),

whichdisplays

key

stepsfor

knowing

what processesto takeintoconsiderationforcompletionofa project. The entireflow

chart possesses a courseofactionsthatcanfulfilla_majorityof projectdemandsthatcomefrom

thePCR.

Themostimportant categoryinvolvesthemeasurementscategory,sinceprojects can or

shouldbemeasured

by

howwell a_packagingengineeris effectively completingtheworkat

hand. The stepslisted intheflowchart aredevelopmentalstepsthata_packagingengineer must

3.2. Needed SoftwareorManagementFunctions

The amountofsoftware functions Duracellneedsto operate and manageonasuccessful

basis shouldbe determined

by

use ofawellthoughtout checklist. Thechecklist(table

1),

developed

by Industry

of

Packaging

Professionals

(IoPP),

displaysthepossible functionsor

requirements _{any company}wouldneedto take into considerationwhen_{managing packaging}

documentationsystems.

Table 1

Automatic

Packaging

Specifications System Checklist

1. Whatneedstobe included?

1.

Packaging

Information- Standard "Boilerplate"

2. Free Text

3. CAD and/orhard copy drawings

4. Attachment files - Text

5. Attachmentfiles- Non-text (scanned _{or computer}

generated)

6. Attachment files- Self

launching

external applications or viewers

7. Label/ Graphics Control 8.

Packaging

Test Methods 9. Approved VendorList

10. BillofMaterial System

2. Whowill use thespecifications?

1. Manufacturing/ Engineering/ Maintenance

2.

Quality

Assurance

3.

Purchasing

4.

Planning

5. Marketing/ Graphic Design

6. Vendors

3. Whatwill we usethespecificationsfor?

1.

Specify

packaging forpurchasing

2. Cost Savings Programs

-Identify

materials and cost_sensitivity 3.

Inventory

Controland Production

Planning

4.

Incoming

inspectionand_{manufacturing}

troubleshooting

5. Guidelinesforgraphicsdesigners

Table 1

(continued)

4. SpecialRequirementsandOpportunities

1. Secureread,write and approval system

2.

GMP,

ISO 9000and other outsiderequirements 3. Obsoleterecord maintenance and_purging

4. Secureand/or publicInternetspecification_availability

5. Specialreport generation

6.

Hardware,

Softwareandbudgetrequirements

Note.Thischecklist was presentedatthe

May

_{1996 meeting} on"Automated

Packaging

Specifications"

oftheNJ ChapterofIoPP: 1996 Andrea S. Mandel.

(Mandel)

The fourcategoriesfromthechecklist

(1)

Whatneedsto be

included?, (2)

Whowilluse

thespecifications?,

(3)

Whatwill we usethespecificationsfor?and,

(4)

Special Requirements

andOpportunitiesare almostall ofthe functionsor requirementsneededfor Duracell's system.

Underthe"Whatneedstobeincluded?"

heading,

an additionalfunctionneedstobeconsidered

for Duracellandother companies_{utilizingpackaging} software managementtools. This function

is "Updates in TechnologicalInnovation,"

which wouldenable constant growth andsoftware

developmentmaturity.

Companies relyuponinformationto passthrougha series ofprocessesbasedon

documentapprovalsinorderforproductstoreachthemarketplacefaster inacontrolled manner.

This gives companiesthecompetitive edgethat

they

needto becomesuccessful. Duracell

technologically

needsweb-based_technology, interfacesoftware(computer_programming)

technology, and server

technology

to n^ximizeitsprocess efficiency.

The IoPPchecklistisausefultoolforanew company's_packagingdepartmentto

help

with_{packaging documentation. A}new company's_{packaging department} might notknow how

togo about_{purchasing documentation}software and mightnot understandalltheproper

The_{Duracell packaging}department needstoimprove and updateitschecklist. The

checklistbelow(table

2)

isan example of what would

help

_{Duracell implement} abettersystem.

Thefunctionsofthissystem andthischecklistwillbe evaluatedthroughout thenewDCS system

inchapter4.

Table 2

Ten Needed SoftwareorManagement Functions

(functionsarelisted inno particular_order)

1. Web-based

technology

2. Oracleserver

3. Security/Controlcapabilities

4.

Daily

automaticback upsystem performed atadowntime

5.

Consistency

of

terminology

6. InterfacewithJ.D. Edwards

7. New BOMformat

8. Greatersearch capabilities

9. Greaterapproval capabilities

10.

Having

DCS functions_effectivelymanage workflow

Source: List created

by Gregory

M. Cullen.

Thereasonto haveweb-based

technology

for Duracellistohavefasterdistributionof

approveddocumentsto theproper_{manufacturing}affiliates.

Currently,

the_packaging department

mails outhardcopies ofdocumentson

Thursday

of_{every business}week.

Therefore,

itisa once

based

technology

would prevent _manyerrorsfrom

happening,

_alongwith_enablingafaster

approval process. Apaperless systemthatreleases most ofthe documentation wouldbe ideal.

Theend result would bea_success, as

long

asit is properlymanaged.

If DuracellhadanOracleserver, itwouldbeabletoprovide amuch morestableand

scaleableplatformthanDCS 2000as aback-end databaseoption. Since DCS 2000atDuracell

uses aMicrosoft Visual FoxProplatform, manyerrors occur

(mostly

computer_glitches) because

of alackofdatabasestability. IfOraclewere_used, itwould enable more

functionally

withinthe

system.

Security

andcontrolcapabilities areimportantprotections for Duracell's

packaging-relatedspecificationdocumentsto ensurethe

integrity

of confidentialdocuments. If documents

wereto get outtoDuracell'scompetitors, itcouldleadtoanuncompetitive edgefor business

profit. Vendorsor suppliers couldhaveunauthorizedaccessto documentsthatare not assigned

tothem.

They

should notbeabletoview_{any documentation}thatdoesnot pertainto them.

Anothergoodfunction isa

daily

automatic systemback up

during

downtime. This

enablesworkto doneatatimewhenitneedstobe (ratherthan

having

userswaitforthe_{back up}

to becomplete).

Currently,

thesystemdoesanautomaticback upor elsedoesthe_morning

updateswhenthefirstemployee logs into DCS 2000each morning. ThisDCS 2000process can

takefrom20to 30minutesto complete. Computerwork_mayneedto be donefirst

thing

inthe

morning.

Therefore,

the systemshould

ideally

be scheduledtorun

independently

inthe

backgroundwithout_needingan employeelog-inandnotat atimewhena greatdealof work

needstobedone.

Consistency

of

terminology

is importantfor Duracell inorderto _clarifywhatis

being

not understandthe_packaging

terminology

being

used ontheBOMs.

Changing

the _{hard copy}

documentof aBOMformatand effective communication arethesolutionsto thisproblem.

AreasonforDuracellto haveaninterfacewithJ.D. Edwardsisto eliminate errorsthat

occur whenthe_supplychaindepartmenthastoretype informationthatcomesfrom BOMs.

Timeissaved

by

not

having

to re-type_packaginginformation.

Duracellshouldhavea newBOMformatto decreaseconfusionthatoccurswith

terminology

and digitvalues. Muchoftheineffectiveness broughtto light

by

thequestionnaire

(appendix

C)

canberesolvedwithadifferent layoutthat incorporatesthe_{hard copy}oftheBOM.

Duracellneedstohavegreater search capabilitiestomake it fasterandeasiertoapprove

neededdocuments.

Being

ableto searchfor dimensionsina_packaging componentthathasthe

samedimensions you are

looking

forcan savetime.

Being

ableto get an exactmatchfora

componentor come closetoan exactmatchforacomponentthatyouneedis an effectivetool.

Having

searchtools that extendbeyond DCS 2000capabilities(search

by

code, documenttype,

status

level,

data

field,

titlephrase, etc.)wouldbeanadvantagefor manyprojectsdoneat

Duracell.

Greaterapproval capabilitiescanbevaluablefor

Duracell,

anditwouldbeenabled with

remindernoticesto approvers andthe_abilityto change auserinthesysteminordertomake

approvals. Ifa_packagingengineerissickorgoes on vacation andadocumentneedsan

approval, thesystemadministratororsomeone couldbe assignedtoapprovethedocument. This

would eliminatetheneedto waitfora_packaging engineerwhoput a_packaging document ina

certain status(suchas

Submitted)

where other engineers couldnotgetto thisdocument tomake

an approval. Remindersforapprovalsfrom DCS would

help

a great

deaf

since_{manypackaging}

throughout thedepartment.

Lastly,

mass approval ofdocuments isanother optionthatwould

facilitate documentapproval.

Thereasonto have_{DCS effectively}manage workflow atDuracellisforguidance

purposes. Ahlevelsof_{packaging engineering}

(entry

to _senior)shouldgetinthehabitof

having

a reference for anyprojectsinfrontofthemat alltimes. Afunctionthatcanrecordandorganize

by

categorizingeachstatuslevelofdocuments

(new,

_{review, submitted,} approval, current, and

3.3.

Avoiding

Obstacles

In evaluatinghundredsof software packages over_{the years,} Dave Garwoodexplains

threeisolatedreasons_{why "computer}solutions" fail:

1

) Company

'sexpectations ofthe software packages_{significantly}exceedthepackages '

capability. _{While customizing}and_modifyingsoftware packages shouldberninimized,

enhancements are_usuallyinevitable.

Writing

programsto interfacewith_existing systems

isoften required. Some features_maybe_{necessary for}one_{company but}notfor_another,

whichis

logical,

sinceit'simpracticalforthesoftware packagesto_{have every}feature

every companyneeds available.

Many

companies purchased a software package and

were_simplynot preparedto

bring

thesoftware capabilities_uptomatchtheirneeds.

2)

Shortcomings insoftwarepackagesare discoveredtoo late. This isthe"Surprise!"

syndrome. Onemight expectthepackagestobe

functionally

complete.

They

aren't. If

missing itemsaren'tdiscovereduntil

deep

into theimplementationprocess,youcan

expect

lengthy

delayswhile programmersfill intheblanks.

3)

Inadequatesupportfrom SystemsandData Processing. Competent Systems/Data

Processing

personnel are a critical_{resource,especially}whenthesoftwareisnot complete.

Whenenhancements or modificationsto software packages are_required,people with a

senseof_urgencyand atrackrecordof_gettingthejob doneare essential. Thereare

educational andbehavioralquestionshereas well. Sometimesprogrammersdon't_really

understandtheuser's needs. This

typically

happensincompanies wheretimeisn't spent

educating Data

Processing

people aswellasusers.

(198-199)

WhatcanDuracelldo toovercome eachofthesethreeobstacles? Thebestanswerfor

Mystic's

history

of_programmingexperienceto itsadvantage. Since Duracell hasworked with

Mystic onits first_software, it is easiertoknowwhattoexpectonthenext_upand _coming

software.

By

having

all areasofdocumentationand managementresearched, aneasier solution will

beachieved.

Effectively

_workingwithMystic

by

together

developing

aspecification

management systemwill

help

Mystic

develop

a softwareversionbasedonDuracell'sneeds.

By

providingthe_necessarymanagementtoolsand

having

thepropertechnicalsupport willmakethe

endresulta successful experience. Standardized

training

foralluserswill

help

educatethem

4. EVALUATIONOF THE DCS 6.0 PRO SYSTEM

4.1. ConditionsofEvaluation

Theconditions usedforDCS 6.0 Pro have beenconducted onthebasisofDuracell's

needs. AnupgradetoDCS 6.0Pro willbedetermined

by

thechanges madetoDCS2000. A

comparison ofDCS 2000andDCS 6.0 Pro willbeexaminedto findthestrengths and

weaknesses ofthe newDCS 6.0system.

AdemonstrationCDofDCS 6.0 Pro _software,an evaluation guidethatcomes withthis

demo,

and questions answered

by

theDCS IT Managerwillbethebasisforthecomparison

between DCS 2000andDCS 6.0 Pro. Documentsused in DCS 2000willbeexaminedin DCS

6.0 Pro throughDuracell'scurrentDCS 2000process of_{creating, approving,} and_releasing

documents.

Thefirst_steptowards _setting conditions was_choosingthe_necessaryfunctionsDuracell

needsinorderto

develop

an_ongoingsuccessful_{packaging departmentoperation,}which was

explainedinchapter3. The second_{step is}to evaluatehowthe tenfunctionswillbe achievedor

accomplishedthrough_{DCS 6.0 Pro. This step}was conductedfrom Mystic's understandingof

howthisnew softwareis_goingtoworkfor Duracell. Thethird _stepisto acknowledgewhat

requirements are neededto operateDCS 6.0 Pro beyondthetenfunctionsneeded. Thefourth

stepisto determineifMystic'snew

technology

and_{pricing for}aDCS 6.0 Proupgradeisa

reasonabledeal.

Ifthechangeshave 90% of whattheneeded changes arefromthe tenneededfunctions

checklist, thena_passingresult willbegiven. _{Fair pricing for}thesoftware mustbenegotiated

savingsDCS 6.0could_potentiallyprovide forDuracell. _{The 90% passing}ratehastoinclude an

effectiveweb-basedcapability. A passingresult will mean arecommendationto_staywith

4.2. Processes Used for Evaluation

The

following

processeshavebeenused toevaluatetheperformanceofDCS 6.0 Pro:

The firstprocess usedfor_evaluatingthe tenfunctionswastogetthe _necessaryquestions

answeredinorderto determineifthetenfunctionscanbeachieved effectively. The IT

Manager,

Dave

Ahrens,

isthe leaderfor

developing

DCS 2000andDCS 6.0 Pro. Hewillbe answering

anyquestions.

The second processforsome ofthetenneededfunctionswillbeevaluated throughuse of

Mystic's DCS 6.0 Pro evaluationdemo. Thetenfunctionswillbeevaluatedto determinewhich

canbeexaminedthroughuse ofthedemo. The functionsthatcannotbeexaminedthroughuse of

thedemo willbeevaluated

by

thequestions answered

by

Dave Ahrens. The neededfunctions

Table 3

Ten Needed Softwareor_{Management Functions}

(D)

(functionsare listedin no particular order

|

1. Web-basedtechnology"

2. Oracleserver

3.

Security

ControlcapabilitiesCD)

4,

Daily

automatic back up system performed atadowntime

5.

Consistency

of_terminology(D)

6. InterfacewithJ.D. Edwards

7. NewBOMformat

8. Greatersearch capabilities (D

)

9. Greaterappro val capabilities

10.

Ha\"ing

DCSfunctions_effectivelymanageworkflow_(D)

Source: Listcreated

by Gregory

M. Cullen

Eachone oftheseneedswillbe_thoroughlyexamined. Functionnumbers4. 7. and 10 on

the checklist_especiallywillbeanalyzed, since Duracell encounters problemswiththese

functions onDCS 2000.

Thethirdprocessis to determine ifanewBOMformat for hard copies couldbe

developed_{for manufacturing} affiliates. Fromthisprocess, a currentversionof aBOMwithin

DCS 2000willbeusedto reformat alayout foranewBOM format hardcopy. Thisprocess

would create a solutionto a majorproblem thatDCS 2000 has developed.

The fourthprocessis providingthedeliverablesneededfor Duracellto implementDCS

The fifthprocessis

having

a cost comparisonbetween DCS 2000andDCS 6.0

Pro,

along

with_anyanalysis ofhowmuchthis

technology

should_{be currentlyworth,} allthingsconsidered.

4.3. Cost Differenceswith theTwo Systems

Description _{Qty Per Cost} Total Cost

Editorial User Licenses- Connecticut Installation

XX $XXXX $xxxx

Editorial User Licenses- Additional Installation in

Germany*

X $XXXX $xxxx

View

Only

User Licenses X $XXXX $xxxx

DCSmail X $XXXX $xxxx

Custom Template Conversion X $XXXX $xxxx

Data Conversion $xxxx

Installation &

Training

$xxxx

Increase in TechnicalSupport Agreement $xxxx

TOTAL UPGRADE PRICE $69,500.00

T

Cost isapplicableifa separateData_Repositorywillbe installedatthis location. Aseparaterepository indicates that a complete and independent system installation of DCS 6.0 _{Professional,} and yet accessible_byotherDuracell locations. Remote locationscan_{have the ability}toaccessthesystem over

aWide Area Network. Ifusers in _Germany are_{accessing the DCS}system via WAN, then_{pricing is}

included in_Bethel, Connecticut location.

Proposal Terms: Proposal iseffectivefor 15 days commencingonOctober9, 2002.

Payment Terms: 50% deposit dueuponacceptance ofproposal, remaining balance dueafter

installation.

(Mystic)

Source: Upgrade Proposal.

MYSTIC MANAGEMENTSYSTEMS, INC.

12Roosevelt Avenue.

Mystic,CT 06355

Invoice

DATE INVOICE#

11/9/98 xxxx

P.O. NO. TERMS PROJECT

On

Receipt

DESCRIPTION RATE AMOUNT

DCS SYSTEM-File Server_{system60concurrent users on single server}

Installationandtesting

Configurationand_Training

Including

DCS Mailmodule

xxxx xxxx

CustomSoftwareDevelopment

Modificationof standard modules

tomeetDuracellrequirements

PCN Template

xxxx xxxx

Cape Interface

Allowance for ConversionofData

xxxx

xxxx

xxxx

xxxx

Payment Terms:

30%on receipt ofinvoice $xxxx

30%onDecember 1 5 $xxxx

30%on systemstart-up (Jan 15,1₉₉₉₎ $xxxx

10% 30 daysafterstart-up $ xxxx

CT Sales Tax xxxx xxxx

Total $88,500.00

The_pricing forDCS 6.0 Pro isestimatedpricing,whichdoesnot includetheresources

Duracellneeds uponinstallation (Oracle

Server,

Website

Server,

etc.).

Currently,

_pricing forthis

newsoftware mightbeundernegotiations. ThecostdifferencebetweenaDCS6.0 Pro upgrade

andthe totalprice ofthe entire systemis_{approximately}$19,000. Theupgradeis clearlyan

economicalchoice. Thisupgrade _{pricing does}not reflect whatthe_pricing wouldbefora

companythat needstodo a complete changeoverof a newspecificationmanagement software

system. Acustomtemplateconversionfor Duracell is approximately$4,500 lessexpensive on

5. RESULTS

5.1. PerspectiveofProcesses Analyzed

Undereach neededfunctiona process _{summary is}presentedforwhatDCS 6.0 Pro canor

cannot accomplishforDuracell.

1. Web-based technology'

DCS 6.0Prohas a companion_product,

DCS.Net,

whichis abrowser-based search

application with password controlled accessfor

locating

and_{retrieving documents. It}usesASP

(Active Server

Pages)

Microsoft Application foraWeb

Component,

whichprovides web-based

searching, viewing,and_printingcapabilitiesfor Duracellaffiliatesthat_{have connectivity}to

Duracell's Wide Area Network (WAN). Aweb-based application reduceshardcopiesof

packagingdocumentationsent outin Duracell's once aweekdistributionprocesstoDuracell's

manufacturingaffiliates. Sincedocumentsare_{electronicallysent,}thecost andtimeof_mailing

BOMsand otherdocumentswill nolonger bea concern. Productionof_packaging components

willbemore effectivebecause_{manufacturing}affiliates will gettheapproveddocumentfaster.

There isalso an e-mail componentthatsupports automaticdistributionofdocumentsto internal

or external e-mail addresses. Thisfunctioncanbe simplynotificationordistribution

by

attachment. Mystichasmade a great achievementtowardsweb-basedtechnology.

2. Oracleserver

For Duracellto_{have any}typeof effective specificationmanagement_system, anOracle

server needstobe_purchased,whichisa separate cost fromtheDCS 6.0 Pro system Oraclehas

thepowerto dealwithdatabase information_storage, andDCS 6.0 Proshouldberun offthis type

moredatabase storage_capabilityforthe_packagingdepartment. It iswritten as alayered

architecturebasedonCOMobjects writtenin VisualBasicversion6.0. DCS 6.0 Pro hasa

front-end_client, also writteninVB 6.0and aview_onlyclient written in ASP (Active Server

Pages)

as

aBrowser-basedapplication. Thesoftware supports either OracleorMS SQL Serveras

back-enddatabaseoptions. Duracellwill need anOracleserverfor

hosting

DCS 6.0 Pro.

Having

an

Oracleserverwillensure a successful resultinthata much more stable and scaleableplatform

willbeprovidedthanwithDCS 2000.

3. Security/controlcapabilities

DCS 6.0 Pro offersbetter securitythanDCS 2000

by

_configuringusernames, passwords,

andtheirrespective affiliated groups. Certaingroups,

departments,

or_companyaffiliatescan

haveaccessto particularfoldersofinformation. DCS 6.0 Pro allowsthemto becomecontrolled

users(determined

by

thesystem_{administrator),} whichallowsthemtorequestdocuments froma

searchengine

by

a_proxyserverthatrelaysto Duracell'ssite. _{From any}

location,

themost

up-to-date documentscanbeaccessed,which createsfewererrors. WhentheDuracellshe receivesthe

request,it isforwarded backto theuser. The system administrator not_onlycontrols who canbe

a_user,butalsowhattypeortypesof_{packaging documentation}a usercanhaveaccessto for

viewing,

downloading,

or_printingpurposes. The way DCS 6.0 Pro is

built,

userswho are not

fromwithinthe_{packaging department} are notallowedto seethefolders ofothertypesof

packaging documentationfromthe

desktop

browserparadigm. Theavailable user controls are

View-Only

access, where users can_onlyviewthecontent of

Approved,

Current and

Historicdocuments. Contributors can_create,edit andifgiventheright,delete

documentsbut

they

cannot approvedocuments.

Approversare grantedtherightstoperform almost_everyfunctionwithintheDCS 6.0

Prosystem, excepttasksassociated with system administration(createusers,groups

document types, etc.)

Administratorsare givenfullaccessto theDCS 6.0 Prosystem;

they

havethe_ability

to configurethesystem settings. (Mystic Evaluation

6)

Fig. 3. DCS 6.0 Pro User Controls.

Theevaluation ofthedemo showedhowthesecontrols(figure

3)

were _successfully

achieved. Appendix Fshows a print screen ofthe demo

displaying

thetemplateusedfor

dealing

withuserrights.

DCS 6.0 Pro supports multipledocument repositories. Each repositorycanbeaccessed

from anysitethatisonthenetwork. Auser wouldneed aDCS6.0 Pro accountto log-into a

givenrepository. Eachuser at a given_repositorycanhaveuniquerightsto thedocument folders.

Auser_maynot evenknowofthe existenceofsome foldersor_{may be}abletonavigatetoother

foldersand not see_{any documents in}thatfolder. Other foldersthatusershaveaccess rightsfor

will enablethem to readthedocumentswithin

it,

whileinstillotherfolders

they

_{may be}given

edit or approval rights. Auser whohas administrativerightsconfiguresall oftheseactions.

Datafieldscanbedefinedas required forapproval,

forcing

usersto _supplya valueto thisfield

before itcanbesubmittedforapproval(Anonymous 3). DCS 6.0 Pro hasmore enhanced

4.

Daily

automaticbackup system performed at a downtime

DCS 6.0 Prouserswillnolongersee orbeawareofa_morningupdateatDuracell. This

new system allows an update processthatruns

independently

inthebackgroundand canbe

scheduledtooccur severaltimesa

day

if desired. The IT

Manager,

Dave

Ahrens,

would

help

Duracellinthedevelopmentofthisprocess. This isa great_result,sincethefirst userinthe

morningwho logsin into DCSwillnothaveto waitto usethe system.

5.

Consistency

ofterminology

ImprovementswithDCS 6.0 Pro includethe_abilityto sort outkeywordsinthe

drop

downsections for_packaging choices andthesearch process.

Having

DCS 6.0 Pro interfacewith

anEnterprise Resource

Planning (ERP)

system,such asJ.D.

Edwards,

will prevent mistakes

by

not

having

a personretype whatis

being

said. Theresultends_up

being

asuccessintermsoftwo

neededfunctions: consistencyof

terminology

andgreater search capabilities. AppendixF

includesa

display

oftheadministrator's capabilities of_accessingatemplate to determinewhat

keywordswillbeused.

Drop

downfieldsthat limittheuser's choice of wordsto

help

produce

theBOMenablesthesystemtomanagewhat

terminology

willbeusedincertain sections ofthe

BOM.

Each

initially

approvedBOMstillneedstobe lookedover

by

a_packagingmanagerto

catch mistakesthatwould mislead_companyaffiliates.

Packaging

engineers'

terminology

inthe

notessectionoftheBOMwillbe less_{confusing to}anaffiliatethatis_usingtheBOM. Thebest

way for Duracelland other companiesto avoid confusionthroughoutinternaland external

affihates isto haveeffective communicationthroughphonecalls,

faxes,

e-mails,and meetings.

Therefore,

words oracronymsfora certainproductorpackagedo notcreateissues. Thisnew

6. InterfacewithJ.D. Edwards

The IT

Manager,

Dave

Ahrens,

can workwithDuracellto

develop

andinterfacetoJ.D.

Edwards,

Duracell'sEnterprise Resource

Planning (ERP)

system.

Packaging

specification

informationwillbe ableto flow fromDCS 6.0 Proto J.D. Edwards. Thiswillbeagreatbenefit

for_{Duracell's supply}chaindepartmentsince

they

willnothavetoretype important information

thatcomesfrom packaging BOMs. Thiswould also eliminate errors thatmightoccurfrom

retyping.

7. New BOM format

To evaluatethep