2. Why AMPPLE?
Purpose
• Accelerator to rapidly develop/deploy a planning tool for production, procurement
and capacity in weekly time buckets across multiple connected organizations – to
enable an integrated S&OP that achieves high service levels with low inventory.
• Tool is flexible to help mitigate the enormous master data challenges posed in a
formal ERP system. The master data can be developed in increments and updated
to develop and validate the operational parameters that are applicable to the
business strategy and the specific manufacturing attributes of items and the
manufacturing capability.
• The tool can be used to understand the rough cut capacity of an environment of
group of connected manufacturing environments in developing annual plans and/or
high-level what-if scenarios.
• The tool has a graphical view to better understand the Demand, Supply and
Inventory by time buckets across the planning horizon. This can be done at an
aggregate level across items or for a specific item (or a group of items).
3. Where AMPPLE?
Best applications at
• Organizations that do not have a
planning tool – may use this as a start
to incrementally develop operational
parameters that can be quickly tested
by developing usable production plans
and then using that master data to
automate the process further by the
use of ERP tools which are restrictive
and time consuming in the deployment
and ability to rapidly change data.
• Venture Capital and Finance firms that
have acquired companies and want to
understand their capacity or have
acquired and merged companies but
do not have an integrated planning
system that can connect all these
entities from manufacturing
dependency perspective.
‘AMPPLE’ history
AMPPLE brings together multiple
industry best practices that we earlier
deployed in pieces at various clients –
✭ for a major pharma firm, developed new
planning tools, 1each for procurement,
production and packing, for use in its supply
chain transformation and to identify
operational parameters,
✭ for an auto supplier facing capacity crunch
adapting to its new demand mix, we
optimized manufacturing lot sizes, to
minimize inventory within the existing
capacity constraints,
– through the use of a novel
comprehensive analytical framework, with
evolved planning functionalities built-in for
quick deployment.
5. How AMPPLE?
For each item, AMPPLE computes MRP-II with MPS, based on best practices.
Derived demand for each child item is BOM expansion of total order in each of its parents.
6. • Complete MRP-II:
o Creates full material requirement plan even for set of items with complex interlinks
o Can also get manufacturing resource plan for labor and capacity usage
• MPS at any level:
o Final plan adheres to scheduled plant uptimes and procurement receipts
o Supports frozen MPS horizons for arbitrary group of items spread at any levels
• Economic Lot Scheduling:
o Economic lot sizes generated, optionally as batch multiples, to minimize total costs
o Currently applies generic costing model with time varying demand using a dynamic lot
sizing model
o Can be configured to adhere to custom partner agreements for procurement
• Spreadsheet based Human Interface
o Simplifies configuration & mitigates master data challenges for quick deployment
What’s AMPPLE?
7. • Versatile MRP supports highly staged Bill-Of-Materials of any complexity, as well as
product transitions
• Integrated supply-chain replenishment visibility, to enable detailed S&OP planning, to
improve service levels with minimum inventory
• Custom planning buckets for faster response to reduce demand time fence
• Firm + exception production/procurement plans facilitate material & production control
and minimizes operational changes thereby reducing operating costs
• Supports both discrete & process manufacturing transformations
AMPPLE Advantages
9. Simple Inputs
Operational parameters and item manufacturing attributes – can be developed
incrementally after an accelerated deployment schedule.
Item
Attributes:
Edit Add Delete
Attrib Item Item
Bill-Of-Material
Bill-Of-
Material:
Change Add Delete
Composition Items Items
Item Attributes
10. • Save development time and accelerate solution development
• Spreadsheet interface for easy configuration to save on deployment
• Quick launch by integrating decentralized knowledge on Lead time, Lot sizing,
Setup, and Inventory holding costs
• Facilitates continuous improvement, and transition from & to other systems
• Preexisting and customizable reports and exception lists
• Can augment existing systems, or run independently for full-fledged planning
• No slippery deadlines; No awaiting data; Sure footed & quick turnaround
AMPPLE Benefits
(contd.)
11. • Data Configuration
o Internal resources best at mobilizing data - item manufacturing attributes and
operational parameters based on business strategy
o We guide, but client shares responsibility for data
• Launches
o Simple MRP launched, then labor & capacity integrated
o MPS production schedules frozen in collaboration with respective planners
• Planning Support
o Solution maintenance and training for changes in Item List, BOM, and other
environmental variables
o Planning hands-on support to ensure positive transformation in SC metrics
Work plan
2 week
Configure
Reconfiguration
Launch
MRP-I
Launch
MRP-II
Develop MPS
2 week 2 week 4 week
Planning
Support & Training
6 week
13. Reporting: Prod/Sales/Inv plan
Detailed PSI plan containing Demand, Supply and Inventory by time buckets that can
be viewed for a specific item or at aggregate level or across group of items.
14. Reporting: Capacity view
Aggregate Capacity View Drilled-down Capacity View
Capacity includes both MPS schedule already frozen as well as additional MRP requirement
and can be viewed for any capacity type.
Capacity report is used to schedule any maintenance and level load capacity via prebuilding
and/or demand management.
Aggregate or Grouped Capacity across the planning horizon for capacity types
based on plan for items that consume that capacity.
15. Reporting: Exception list
Due Plan-Order Releases
conveys production that is due now or
could miss timely demand fulfillment.
Value of Excess Proj. Available Balance at the
end of planning horizon, due to: high opening inv. or open
Plan Orders or oversized batch sizes.
