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How to Improve and Accelerate your S&OP process



                       April 20th 2010

               Logichem Düsseldorf




                         Elke Servaes
                    Senior Consultant


                OM Partners © Proprietary and Confidential   - p. 1 -
Contents


  The OM Partners Group:                                                       5 min
   - Who we are
   - What we do


  How to improve & accelerate your S&OP process with OMP Plus                  35 min
   - S&OP?
   - S&OP according to OM Partners




                           OM Partners © Proprietary and Confidential   - p. 2 -
Contents


  The OM Partners Group:
   - Who we are
   - What we do


  How to improve & accelerate your S&OP process with OMP Plus
   - S&OP?
   - S&OP according to OM Partners




                           OM Partners © Proprietary and Confidential   - p. 3 -
The OM Partners Group: Activity


OM Partners = Provider of Demand and Supply Chain Planning Solutions
                                                           Solutions

    SUPPLY
   SUPPLY          MANUFACTURING
                   MANUFACTURING                          DISTRIBUTION
                                                         DISTRIBUTION    DEMAND
                                                                         DEMAND




                         OM Partners © Proprietary and Confidential      - p. 4 -
The OM Partners Group: History


  Founded in 1985
   - Strong roots in Mathematical Optimization
   - Subsequent evolution towards Supply Chain Solutions


  Key figures
   - Personnel   : 130 employees
   - Turnover    : 15.5 mio €
   - Clients     : over 200 clients and 400 implementations




                             OM Partners © Proprietary and Confidential   - p. 5 -
The OM Partners Group: International Structure


Headquarters         OM Partners (Antwerpen)




Subsidiaries
  - OM Partners France               - OM Partners Deutschland
  - OM Partners Nederland            - OM Partners USA
  - OM Partners UK                   - OM Partners Asia


                            OM Partners © Proprietary and Confidential   - p. 6 -
The OM Partners Group: Business Partners


  Integration and consulting partners
   -   Accenture
   -   Capgemini
   -   Tieto
   -   Vest Company
   -   Wipro Technologies
   -   …
  Solution partners
   - Radar Automation
   - Ortec
  Software integration with
   -   Oracle
   -   SAP
   -   AICOMP
   -   Solarsoft Packaging Systems
   -   Business Objects (Crystal Reports)
   -   MapInfo
                               OM Partners © Proprietary and Confidential   - p. 7 -
The OM Partners Group: Focus Industries

  Mill Products
  Corrugated and solid board, paper                       Metals, plastics, flooring, …




  Semi Process
  Chemicals, pharmaceuticals, starch, …                                                      dairy…
                                                          Consumer goods, food and beverage, dairy…




                                  OM Partners © Proprietary and Confidential              - p. 8 -
customers…
The OM Partners Group: Some of our customers…




                       OM Partners © Proprietary and Confidential   - p. 9 -
chain…
Our added value to your supply chain…




      VISIBILITY


                                                                     AGILITY


          PROFITABILITY

                        OM Partners © Proprietary and Confidential       - p. 10 -
Overview Planning processes in OMP Plus
 Strategic




                              Supply Chain Network Design
                              Supply Chain Network Design


                  Inventory Optimization & Product Portfolio Optimization
                   Inventory Optimization & Product Portfolio Optimization                     Forecasting
                                                                                               Forecasting
 Tactical




                               Sales & Operations Planning
                               Sales & Operations Planning



                 Supply, Manufacturing, DRP & Transport Planning
                 Supply, Manufacturing, DRP & Transport Planning
 Operational




                                                                                      Order Management,
                                                                                      Order Management,
                                                                                          Allocation
                                                                                           Allocation
               Supply, Manufacturing, Loading & Transport Scheduling
               Supply, Manufacturing, Loading & Transport Scheduling                     & Promising
                                                                                         & Promising



               Supply             Manufacturing                        Distribution       Demand



                                  OM Partners © Proprietary and Confidential              - p. 11 -
Supported by only one tool… OMP Plus Next Level
OMP Plus: Taking Integration To The




                                      Chain Network Design Multi-
                               Supply Multi- Network Design Multi-Language
  Strategic




                               Supply Multi-User
                                      Chain


                                Multi-
                                Multi-Site
                   Inventory Optimization & Product Portfolio OptimizationModular                     Forecasting
                    Inventory Optimization & Product Portfolio Optimization                           Forecasting
  Tactical




                                Sales & Operations Planning
                                Sales & Operations Planning

                                                                                       In memory integration

                  Supply, Manufacturing, DRP & Transport Planning
                  Supply, Manufacturing, DRP & Transport Planning
  Operational




                                                                                             Order Management,
                                                                                             Order Management,
                                                  Common Data Model                              Allocation
                                                                                                  Allocation
                Supply, Manufacturing, Loading & Transport Scheduling
                Supply, Manufacturing, Loading & Transport Scheduling                           & Promising
                                                                                                & Promising
                                                      Central database

                Supply             Manufacturing                        Distribution             Demand



                                   OM Partners © Proprietary and Confidential                    - p. 12 -
software…
The OM Partners Solution: more than just software…


     Values                                                           Services

       - Visibility                                                    - Business consultancy

       - Agility                                                       - Implementation

       - Profitability                                                 - Support Services




     Our Solutions = Software Products + Services + Commitment


                                 Our Commitment =

                                   To make it work
                                  To keep it running

                         OM Partners © Proprietary and Confidential               - p. 13 -
Contents


  The OM Partners Group
   - Who we are
   - What we do


  How to improve & accelerate your S&OP process with OMP Plus
   - S&OP?
   - S&OP according to OM Partners




                           OM Partners © Proprietary and Confidential   - p. 14 -
Planning…
Sales & Operations Planning…..




                        OM Partners © Proprietary and Confidential   - p. 15 -
idea…
Why S&OP ? The general idea…


 If supply > demand:

 • Rising inventories
 • Declining profit margins
 • Obsoletes
 •…



                                                                           If demand > supply:

                                                                           • Suffering customer service
                                                                           • Cost increases
                                                                             (overtime, premium freight, …)
                                                                           • Quality decrease because of rush
                                                                           •…


             Main goal of S&OP : balance supply & demand


                              OM Partners © Proprietary and Confidential                    - p. 16 -
… more in detail: S&OP definition (by Thomas Wallace)

 Sales and Operations Planning (S&OP) is a business process that helps companies keep demand and
           balance.
 supply in balance.

 It does that by focusing on aggregate volumes (product families and groups) so that mix issues
 (individual products and customer orders) can be handled more readily.
                                                                 readily.

                                                                         dollars,
 It occurs on a monthly cycle and displays information in both units and dollars, thus it integrates
 operational and financial planning.

 S&OP is crossfunctional, involving General Management, Sales, Operations, Finance and Product
         crossfunctional,                                                              Product
 Development.

 It occurs at multiple levels within the company, up to and including the executive in charge of the
           unit,
 business unit, e.g. division president, business unit general manager, or CEO of a smaller corporation.

 S&OP links the company’s Strategic Plans and Business Plan to its detailed processes – the order
                 company’
 entry, master scheduling, plant scheduling, and purchasing tools it uses to run the business on a week-
                                                                                                   week-
 to-week, day-to-day, and hour-to-hour basis.
 to-      day-to-         hour-to-

 Used properly, S&OP enables the company’s managers to view the business holistically and gives them
                                 company’
 a window into the future.

        Source : Thomas F. Wallace, Sales & Operations Planning: The How-To Handbook 2nd edition, 2004
                                       OM Partners © Proprietary and Confidential              - p. 17 -
S&OP: General


  S&OP is not only / just a planning process that balances Supply and Demand,
  but a management process
   -    Involving people from sales, operations, finance,…
   -    With a well described process description
   -    Following a certain workflow
   -    Requiring quite some change management in peoples thinking


  The S&OP process should be the missing link between
   - The corporate business strategy
   - The operational day to day planning
                                 operationalizing”
       A big pitfall: Beware of “operationalizing” the S&OP process

  Integration with these strategic and operational planning levels
   - Overall consensus: is important




                               OM Partners © Proprietary and Confidential   - p. 18 -
S&OP: The process description

      TRADITIONAL SEQUENTIAL APPROACH
                                                                           Data collection and preparation:
1.    Collect sales and marketing information                                 -   sales/marketing events
                                                                              -   product life cycle
2.           Develop a demand plan                                            -   statistical forecasting
                                                                              -   current performance, …
3. Generate an unconstrained consensus forecast
                                                                           Demand review:
                                                                              - unconstrained forecast
4.       Shape the demand plan for supply
                                                                           Supply review:
                                                                              - constrained plan
5.        Make a constrained supply plan
                                                                           Financial impact calculation
6.            Shape demand plan                                            Reconciliation step / Pre-S&OP meeting:
                                                                              - What-if analysis
7.         Review the financial impact                                        - SWOT analysis
                                                                           Consensus meeting / Senior
8.         Communicate the sales plan                                      management review / Executive S&OP
                                                                           meeting
9.      Measure and communicate the plan                                   Communication of decisions


             Typically a few weeks
                                            OM Partners © Proprietary and Confidential                      - p. 19 -
S&OP: The process description


  Although two typical approaches can be derived:

   - Spreadsheet/simulation approach
        .   Flexible way to enter information
        .   Sequential demand, supply and financial review
        .   Trial-and-error process


   - Optimization approach
        .   Demand, supply and finance should be considered simultaneously
        .   Precise definition of scope, constraints and objective function is required
               consistency in S&OP process
        .   Strategic decisions can be taken into account (modeled as constraints)




                                    OM Partners © Proprietary and Confidential            - p. 20 -
Contents


  The OM Partners Group
   - Who we are
   - What we do


  How to improve & accelerate your S&OP process with OMP Plus
   - S&OP?
   - S&OP according to OM Partners




                           OM Partners © Proprietary and Confidential   - p. 21 -
trade-
    OM Partners S&OP Approach: the basic trade-offs

Capacity                                                                       Demand
+ overtime, hiring, extra machines,                                            + marketing actions, price reductions, …
  subcontracting, …                                                            - premium pricing, product/customer
- downtime, firing, …                                                            portfolio rationalization
$ variable costs + direct fixed                                                $ sales price
  costs




                              Inventory
                              + anticipation stock accumulation
                              - stock build-offs
                              $ stock holding costs


                      Make trade-offs while maximizing value:
               expressed as contribution to profit, taking into account
           gross margin - direct fixed costs and working capital constraints

                                      OM Partners © Proprietary and Confidential                   - p. 22 -
OM Partners S&OP Approach (1)


  OMP Plus: integrated planning levels
    integration between S&OP module and:
   - Strategic decisions
   - Forecasting / demand module
                                                                                       Visibility
   - Operational (Master Planning and Scheduling) modules
     Strategic




                                  Supply Chain Network Design
                                  Supply Chain Network Design                                             Agility

                      Inventory Optimization & Product Portfolio Optimization
                       Inventory Optimization & Product Portfolio Optimization        Forecasting
                                                                                      Forecasting
     Tactical




                                   Sales & Operations Planning
                                   Sales & Operations Planning


                     Supply, Manufacturing, DRP & Transport Planning
                     Supply, Manufacturing, DRP & Transport Planning
     Operational




                                                                         Order Management,
                                                                         Order Management,
                                                                             Allocation
                                                                              Allocation
                   Supply, Manufacturing, Loading & Transport Scheduling
                   Supply, Manufacturing, Loading & Transport Scheduling    & Promising
                                                                            & Promising

                       Supply          Manufacturing                 Distribution    Demand

                                        OM Partners © Proprietary and Confidential            - p. 23 -
OM Partners S&OP Approach (2)

       The S&OP process: optimization approach
         -    Simultaneously looking at demand, supply and finance
         -    Including strategic business rules
         -    While maximizing value: value based planning
         -    Shorter planning / process cycles                                                    Profitability

      TRADITIONAL SEQUENTIAL APPROACH                                                                                           Agility
1.    Collect sales and marketing information                                              INTEGRATED OMP PLUS APPROACH

2.             Develop a demand plan                                             1.        Collect sales and marketing information

3. Generate an unconstrained consensus forecast
                                                                                 2.        Develop a demand plan with sales prices
4.       Shape the demand plan for supply
                                                                                 3.          Generate a supply and demand plan
5.           Make a constrained supply plan                                                         optimized for value
                                                                                                      Optimized for
6.              Shape demand plan                                                                     highest value
                                                                                 4.              Evaluate optimized scenarios
7.           Review the financial impact                                                           and reach a consensus

8.           Communicate the sales plan                                          5.             Communicate the sales plan

9.      Measure and communicate the plan                                         6.          Measure and communicate the plan


                Typically a few weeks                                                             Typically a few days
                                              OM Partners © Proprietary and Confidential                           - p. 24 -
OM Partners S&OP approach (3): Process description




S&OP preparation
•   Demand
•
                          Pre
                          Pre-S&OP:                                                    Plan
    Supply                                                         Executive
•   Finance          alue-
                    value-based, integrated                                        communication
                                                                  S&OP meeting
•   New product          reconciliation                                             & execution
    & process
    development




                                OM Partners © Proprietary and Confidential       - p. 25 -
S&OP process description: step 1




S&OP preparation
•   Demand
                         Pre
                         Pre-S&OP:                                                    Plan
•   Supply                                                        Executive
•   Finance         alue-
                   value-based, integrated                                        communication
                                                                 S&OP meeting
•   New product         reconciliation                                             & execution
    & process
    development




                               OM Partners © Proprietary and Confidential       - p. 26 -
Planning Functionality: Overview


                   Supply Chain Network Design
                   Supply Chain Network Design
     Strategic




                                      Supply Chain Network Design
                                      Supply Chain Network Design

    Inventory Optimization & Product Portfolio Optimization
     Inventory Optimization & Product Portfolio Optimization                                 Forecasting
                                                                                             Forecasting
                        Inventory Optimization & Product Portfolio Optimization
                         Inventory Optimization & Product Portfolio Optimization                      Forecasting
                                                                                                      Forecasting
     Tactical




                   Sales & Operations Planning Operations Planning
                   Sales & Operations Planning Operations Planning
                                       Sales &
                                       Sales &

                                                                                                                    ERP
                                                                                                                    ERP
                                                                                                                     &
                                                                                                                     &
                         Supply, Manufacturing, DRP & Transport Planning
                         Supply, Manufacturing, DRP & Transport Planning                                            MES
                                                                                                                    MES
  Supply, Manufacturing, DRP & Transport Planning
  Supply, Manufacturing, DRP & Transport Planning
     Operational




                                                                                     Order Management,
                                                                                     Order Management,
                                                                            Order Management,
                                                                            Order Management,
                                                                                AllocationAllocation
                                                                                 AllocationAllocation
                      Supply, Manufacturing, Loading & Transport Scheduling
                      Supply, Manufacturing, Loading & Transport Scheduling              & Promising
                                                                               & PromisingPromising
                                                                                          &
                                                                               & Promising

Supply, Manufacturing, Loading & Transport Scheduling
Supply, Manufacturing, Loading & Transport Scheduling
                    Supply             Manufacturing                          Distribution         Demand

                                    OMP FEEDBACK MANAGER
                                    OMP FEEDBACK MANAGER
                                         OM Partners © Proprietary and Confidential                - p. 27 -
Step 1a : Integrated Demand preparation


               Supply Chain Network Design                                    Visibility
               Supply Chain Network Design
                                                                                             Forecasting:
                                                                                             Forecasting:       Sales
                                                                                                                history
    Inventory Optimization & Product Portfolio Optimization
     Inventory Optimization & Product Portfolio Optimization                                  Forecasting
                                                                                              Forecasting
                                                                                             Statistical fcst
                                                                                             Statistical fcst
                                                                           Unconstrained       PLC mgmt
                                                                                               PLC mgmt
                                                                             forecast       Promotion mgmt
                                                                                            Promotion mgmt

                                                                             Sales prices
                Sales & Operations Planning
                Sales & Operations Planning
                                                                                                                          ERP
                                                                                                                          ERP
                                                                                                                           &
                                                                                                                           &
                                                                                                                          MES
                                                                                                                          MES

  Supply, Manufacturing, DRP & Transport Planning
  Supply, Manufacturing, DRP & Transport Planning                                      Order Management,
                                                                                       Order Management,
                                                                                           Allocation
                                                                                            Allocation
                                                                                          & Promising
                                                                                          & Promising

Supply, Manufacturing, Loading & Transport Scheduling
Supply, Manufacturing, Loading & Transport Scheduling



                                   OMP FEEDBACK MANAGER
                                   OMP FEEDBACK MANAGER
                                        OM Partners © Proprietary and Confidential                  - p. 28 -
Integrated Forecasting / S&OP View




      S&OP Pyramid                                                                  Forecast graph
                                                                                     of selection




                                                                                                    Year Totals
                        Past Months                                  Generate unconstrained
                                                                        S&OP forecast




                        OM Partners © Proprietary and Confidential                      - p. 29 -
Step 1b : Integrated (operational) Supply preparation


                Supply Chain Network Design
                Supply Chain Network Design

                                                                                     Visibility                       Sales
                                                                                                                      history
    Inventory Optimization & Product Portfolio Optimization
     Inventory Optimization & Product Portfolio Optimization                                        Forecasting
                                                                                                    Forecasting
                                                                                  Unconstrained
                                                                                    forecast
                Sales & Operations Planning
                Sales & Operations Planning
                                                                                    Sales prices
                           -Planning Model
                            Planning
                           -Planning Model
                            Planning
         (prod., transp., purch. and subcontr. capabilities)
          (prod., transp., purch. and subcontr. capabilities)                                                                   ERP
                                                                                                                                ERP
                            -- Supply costs
                               Supply costs
                                                                                                                                 &
                                                                                                                                 &
                                                                                                                                MES
                                                                                                                                MES
         Plan + stock

  Supply, Manufacturing, DRP & Transport Planning
  Supply, Manufacturing, DRP & Transport Planning                                             Order Management,
                                                                                              Order Management,
                                                                                                  Allocation
                                                                                                   Allocation
         Schedule                                                                                & Promising
                                                                                                 & Promising

Supply, Manufacturing, Loading & Transport Scheduling
Supply, Manufacturing, Loading & Transport Scheduling



                                        OMP FEEDBACK MANAGER
                                        OMP FEEDBACK MANAGER
                                               OM Partners © Proprietary and Confidential                 - p. 30 -
Zoom in on supply planning : integrated with all planning levels



                      Days                             Weeks              Months



    S&OP




MPS/deployment




  Scheduling




                             OM Partners © Proprietary and Confidential            - p. 31 -
Integrated Supply / S&OP View

             Scheduled productions are
               input for S&OP cycle
                                                                                      Month/Quarter buckets




S&OP Plan line




Campaign Gantt




                                         OM Partners © Proprietary and Confidential                    - p. 32 -
Step 1b : Integrated (strategic) Supply preparation


                 Supply Chain Network Design
                 Supply Chain Network Design

          LT capacity & Location decisions                                            Visibility                       Sales
                                                                                                                       history
    Inventory Optimization & Product Portfolio Optimization
     Inventory Optimization & Product Portfolio Optimization                                         Forecasting
                                                                                                     Forecasting

          Safety Stocks                                                             Unconstrained
                                                                                      forecast
                 Sales & Operations Planning
                 Sales & Operations Planning
                                                                                     Sales prices
                            -Planning Model
                             Planning
                             -Planning Model
                              Planning
          (prod., transp., purch. and subcontr. capabilities)
           (prod., transp., purch. and subcontr. capabilities)                                                                   ERP
                                                                                                                                 ERP
                      -- Supply costs // Sales prices
                         Supply costs Sales prices                                                                                &
                                                                                                                                  &
                                                                                                                                 MES
                                                                                                                                 MES
           Plan + stock

  Supply, Manufacturing, DRP & Transport Planning
  Supply, Manufacturing, DRP & Transport Planning                                              Order Management,
                                                                                               Order Management,
                                                                                                   Allocation
                                                                                                    Allocation
          Schedule                                                                                & Promising
                                                                                                  & Promising

Supply, Manufacturing, Loading & Transport Scheduling
Supply, Manufacturing, Loading & Transport Scheduling



                                         OMP FEEDBACK MANAGER
                                         OMP FEEDBACK MANAGER
                                                OM Partners © Proprietary and Confidential                 - p. 33 -
Integrated Strategic balancing / S&OP View



   S&OP for 3 plants
                                                                            Demand & Supply plan
                                                                                  for Plant A
                                                                            (1 Year Aggr. Bucket)




                                                                          Strategic Restricted Capacity
                                                                           for machine A1 (based on
                        Theoretically available                           strategic balancing between
                       capacity on machine A1                                        plants)




                                                                            Compared to used
                         Used capacity on                                 capacity on machine A1
                         machine A1 (95%)                                         (104%)

                             OM Partners © Proprietary and Confidential                    - p. 34 -
S&OP process description: step 2




S&OP preparation
•   Demand
                         Pre
                         Pre-S&OP:                                                    Plan
•   Supply                                                        Executive
•   Finance         alue-
                   value-based, integrated                                        communication
                                                                 S&OP meeting
•   New product         reconciliation                                             & execution
    & process
    development




                               OM Partners © Proprietary and Confidential       - p. 35 -
Pre       value-       integrated
Step 2 : Pre-S&OP: value-based, integrated reconciliation

Review past performance: analyze gaps with previous plan
            performance:

Make base scenario
 - Take unconstrained forecast                                                                            Agility
 - Apply minimal supply constraints

                                                                                   Profitability
Make gap analysis
 - Compare base scenario with previous S&OP plan, corporate targets, …
                                                            targets,


                                                                   trade-
Make alternative demand and supply scenarios based on typical S&OP trade-offs
 -   Derived from base scenario and gap analyses
 -   Value-
     Value-based optimization of each scenario
 -   Demand shaping
 -   Prepare KPI view on scenarios


Reconcile demand, supply and finance views
 - Evaluate alternative scenarios
 - Select key scenarios


Prepare executive review
                                      OM Partners © Proprietary and Confidential              - p. 36 -
Value Based Optimization

             Value driver tree                     S&OP objective function          Relationship with
                                                                                    S&OP decisions
                                   Sales
                                   Sales             (+) sales prices
                                                     (+) sales prices               Select the most profitable
                                                                                    demand
                Contribution
                Contribution
      EBIT
      EBIT        margin
                  margin          Variable            (-) variable costs, incl.     Select most cost efficient
                                  Variable            (-) variable costs, incl.     supply, production,
                                   costs
                                   costs              non-financial stock costs
                                                      non-financial stock costs     transport, stocking

 EBIT
 EBIT                              Fixed
                                   Fixed                                            Fixed costs directly linked
                                                      (-) only direct fixed costs
                                                      (-) only direct fixed costs   to S&OP decisions
 after
 after                             costs
                                   costs                                            Non-direct fixed costs
capital
capital                                                                             should be left out and not
 costs
 costs                                                                              converted into variable
                                                                                    costs
                                  Working
                                  Working            (-) financial stock costs
                                                     (-) financial stock costs      E.g. optimize stock levels,
                     Total
                     Total        Capital
                                  Capital            subject to: working capital
                                                     subject to: working capital    payment terms in different
                                                     constraints                    markets, …
                 investment
                  investment                         constraints
     Capital
     Capital                     Permanent
                                  Permanent
      costs
      costs                      Investments
                                 Investments
                Percentage
                Percentage
                capital costs
                capital costs


                                      OM Partners © Proprietary and Confidential      - p. 37 -
Value based optimization

                                                                           Profitability
               Supply Chain Network Design
               Supply Chain Network Design

          LT capacity & Location decisions                                                                     Sales
                                                                                                               history
    Inventory Optimization & Product Portfolio Optimization
     Inventory Optimization & Product Portfolio Optimization                                 Forecasting
                                                                                             Forecasting
          Safety Stocks                                                    Unconstrained
                                                                             forecast
                                                                             Sales prices

                Sales & Operations Planning
                Sales & Operations Planning
                                                                                                                         ERP
                                                                                                                         ERP
                                                                                                                          &
                                                                                                                          &
                                                                                                                         MES
                                                                                                                         MES
          Plan + stock
                                                                                       Order Management,
                                                                                       Order Management,
  Supply, Manufacturing, DRP & Transport Planning
  Supply, Manufacturing, DRP & Transport Planning                                          Allocation
                                                                                            Allocation
                                                                                          & Promising
                                                                                          & Promising
          Schedule

Supply, Manufacturing, Loading & Transport Scheduling
Supply, Manufacturing, Loading & Transport Scheduling


                                   OMP FEEDBACK MANAGER
                                   OMP FEEDBACK MANAGER
                                        OM Partners © Proprietary and Confidential                 - p. 38 -
Solver Strategies: Scenario Management


  Limited Capacity vs. Capacity with extra shift
      Base scenario




                                                                          Shift   Base




      With extra shift




                             OM Partners © Proprietary and Confidential              - p. 39 -
S&OP process description: step 3




S&OP preparation
•   Demand
                          Pre
                          Pre-S&OP:                                                   Plan
•   Supply                                                        Executive
•   Finance        value-based, integrated
                    alue-                                                         communication
                                                                 S&OP meeting
•   New product         reconciliation                                             & execution
    & process
    development




                               OM Partners © Proprietary and Confidential       - p. 40 -
Step 3 : Executive S&OP meeting


  Review past performance

  Decision making on key scenarios
                                                                               Agility
   - Validation based on KPIs, assumptions and SWOT analysis
   - Tie-breaking when pre-S&OP was unable to reach consensus
     Tie-              pre-
   - Check alignment with business plan / budget & corporate strategy                          Visibility

  Define action plan
   - Actions on gaps between plan and performance
   - Actions on consensus plan
   - What-if scenarios for evaluation in next S&OP cycles
     What-




  Who
   - Senior managers from supply, sales and finance
   - Key-users from supply, sales and finance
     Key-


                                  OM Partners © Proprietary and Confidential       - p. 41 -
KPI report: Scenario Management


                Different Scenarios



                                                                                                  KPI’
                                                                                        Different KPI’s




                                                                                        Scenario
                                                                                     Comparison chart




                            OM Partners © Proprietary and Confidential   - p. 42 -
KPI report: Capacity report




                                                                                             KPI’
                                                                                   Different KPI’s




                          OM Partners © Proprietary and Confidential   - p. 43 -
KPI report: Service Levels and Inventory report




                        KPI Alerts


                          OM Partners © Proprietary and Confidential   - p. 44 -
OMP Reporter: Crystal Reports and Scenario Management




                       OM Partners © Proprietary and Confidential   - p. 45 -
OMP Reporter : OLAP cubes


  OLAP Cubes
   - An OLAP (OnLine Analytical Processing) Cube is a data structure that allows fast and
     flexible analysis of data
   - Based on a set of predefined “measures” categorized by dimensions
                                    measures”
   - The tool allows to view or “pivot” the data in numerous ways
                                 pivot”




                              OM Partners © Proprietary and Confidential   - p. 46 -
S&OP process description: step 4




S&OP preparation
•   Demand
                          Pre
                          Pre-S&OP:                                                   Plan
•   Supply                                                        Executive
•   Finance        value-based, integrated
                    alue-                                                         communication
                                                                 S&OP meeting
•   New product         reconciliation                                             & execution
    & process
    development




                               OM Partners © Proprietary and Confidential       - p. 47 -
Step 4: Integrated communication


                 Supply Chain Network Design
                 Supply Chain Network Design                                   Visibility
            LT capacity & Location decisions                                                                        Sales
                                                                                                                    history
      Inventory Optimization & Product Portfolio Optimization
       Inventory Optimization & Product Portfolio Optimization                                    Forecasting
                                                                                                  Forecasting
            Safety Stocks                                                   Unconstrained
                                                                              forecast
                  Sales & Operations Planning
                  Sales & Operations Planning                                Sales prices
                                                                              Constrained
                Operations plan                                                forecast              SKU constrained
    Plan                                                                                             forecast                 ERP
                                                                                                                              ERP
                • Sourcing
      +         • Stock targets
                                                                                                                               &
                                                                                                                               &
    stock                                                                                                                     MES
                                                                                                                              MES
                • Capacity decisions

    Supply, Manufacturing, DRP & Transport Planning
    Supply, Manufacturing, DRP & Transport Planning                                         Order Management,
                                                                                            Order Management,
                                                                                                Allocation
                                                                                                 Allocation
Schedule                                                                                       & Promising
                                                                                               & Promising

  Supply, Manufacturing, Loading & Transport Scheduling
  Supply, Manufacturing, Loading & Transport Scheduling



                                     OMP FEEDBACK MANAGER
                                     OMP FEEDBACK MANAGER
                                          OM Partners © Proprietary and Confidential                    - p. 48 -
Zoom in on supply planning : integrated with all planning levels



                      Days                             Weeks              Months



    S&OP




MPS/deployment




  Scheduling




                             OM Partners © Proprietary and Confidential            - p. 49 -
Integrated S&OP/Supply (MPS) view




                                                                     S&OP view with
                                                                    monthly aggregated
                                                                       buckets and
                                                                    product family level




                                                                      MPS view with
                                                                    weekly buckets and
                                                                       product level




                       OM Partners © Proprietary and Confidential           - p. 50 -
S&OP process description




S&OP preparation
•   Demand
                          Pre
                          Pre-S&OP:                                                   Plan
•   Supply                                                        Executive
•   Finance        value-based, integrated
                    alue-                                                         communication
                                                                 S&OP meeting
•   New product         reconciliation                                             & execution
    & process
    development




                               OM Partners © Proprietary and Confidential       - p. 51 -
S&OP with OMP Plus in a mixed vendor landscape (eg. SAP)


      Forecast and demand plan
                                              APO                                                  S&OP in OMP Plus
                                               DP
                                                                                         • S&OP integrated with forecasting, planning
    SAP R/3                                                                                and scheduling
                                                                                         • Consolidated, Intuitive Forecasting, Planning
                                                                                           and Scheduling views
                                              SNP                                        • Views including Historical Plan/Realization data
  Historical sales, distribution
  and production data
                                                                                         • Scenario Management
                                                                                         • Powerful End to End Optimization Engines
Supply plan on finished good level


                                            PP/DS
Short term supply schedule                                                                    Supporting an integrated and
                                                                                               collaborative S&OP Process


                                     • Fragmented processes




                                                     OM Partners © Proprietary and Confidential                         - p. 52 -
OMP Plus as an S&OP Solution: more than just software




           Strategic
                                              Supply Chain Network Design
                                              Supply Chain Network Design

                                  Inventory Optimization & Product Portfolio Optimization
                                   Inventory Optimization & Product Portfolio Optimization         Forecasting
                                                                                                   Forecasting
           Tactical
                                               Sales & Operations Planning
                                               Sales & Operations Planning


                                 Supply, Manufacturing, DRP & Transport Planning
                                 Supply, Manufacturing, DRP & Transport Planning
           Operational




                                                                                             Order Management,
                                                                                             Order Management,
                              Supply, Manufacturing, Loading & Transport Scheduling
                              Supply, Manufacturing, Loading & Transport Scheduling              Allocation
                                                                                                  Allocation
                                                                                                & Promising
                                                                                                 & Promising

                               Supply             Manufacturing             Distribution         Demand




                                                Visibility                   Agility                    Profitability
                  S&OP preparation
                  •      Demand
                  •      Supply                 Pre
                                                Pre-S&OP:                                         Plan
                                                                          Executive
                  •      Finance         value-based, integrated
                                          alue-                                               communication
                                                                         S&OP meeting
                  •      New product          reconciliation                                   & execution
                         & process
                         development




                                             OM Partners © Proprietary and Confidential                          - p. 53 -
Thank you



                                               eservaes@ompartners.com
                                                   www.ompartners.com

  OM Partners © Proprietary and Confidential
                                                      - p. 54 -

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Chemical Supply Chain

  • 1. How to Improve and Accelerate your S&OP process April 20th 2010 Logichem Düsseldorf Elke Servaes Senior Consultant OM Partners © Proprietary and Confidential - p. 1 -
  • 2. Contents The OM Partners Group: 5 min - Who we are - What we do How to improve & accelerate your S&OP process with OMP Plus 35 min - S&OP? - S&OP according to OM Partners OM Partners © Proprietary and Confidential - p. 2 -
  • 3. Contents The OM Partners Group: - Who we are - What we do How to improve & accelerate your S&OP process with OMP Plus - S&OP? - S&OP according to OM Partners OM Partners © Proprietary and Confidential - p. 3 -
  • 4. The OM Partners Group: Activity OM Partners = Provider of Demand and Supply Chain Planning Solutions Solutions SUPPLY SUPPLY MANUFACTURING MANUFACTURING DISTRIBUTION DISTRIBUTION DEMAND DEMAND OM Partners © Proprietary and Confidential - p. 4 -
  • 5. The OM Partners Group: History Founded in 1985 - Strong roots in Mathematical Optimization - Subsequent evolution towards Supply Chain Solutions Key figures - Personnel : 130 employees - Turnover : 15.5 mio € - Clients : over 200 clients and 400 implementations OM Partners © Proprietary and Confidential - p. 5 -
  • 6. The OM Partners Group: International Structure Headquarters OM Partners (Antwerpen) Subsidiaries - OM Partners France - OM Partners Deutschland - OM Partners Nederland - OM Partners USA - OM Partners UK - OM Partners Asia OM Partners © Proprietary and Confidential - p. 6 -
  • 7. The OM Partners Group: Business Partners Integration and consulting partners - Accenture - Capgemini - Tieto - Vest Company - Wipro Technologies - … Solution partners - Radar Automation - Ortec Software integration with - Oracle - SAP - AICOMP - Solarsoft Packaging Systems - Business Objects (Crystal Reports) - MapInfo OM Partners © Proprietary and Confidential - p. 7 -
  • 8. The OM Partners Group: Focus Industries Mill Products Corrugated and solid board, paper Metals, plastics, flooring, … Semi Process Chemicals, pharmaceuticals, starch, … dairy… Consumer goods, food and beverage, dairy… OM Partners © Proprietary and Confidential - p. 8 -
  • 9. customers… The OM Partners Group: Some of our customers… OM Partners © Proprietary and Confidential - p. 9 -
  • 10. chain… Our added value to your supply chain… VISIBILITY AGILITY PROFITABILITY OM Partners © Proprietary and Confidential - p. 10 -
  • 11. Overview Planning processes in OMP Plus Strategic Supply Chain Network Design Supply Chain Network Design Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Tactical Sales & Operations Planning Sales & Operations Planning Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Operational Order Management, Order Management, Allocation Allocation Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling & Promising & Promising Supply Manufacturing Distribution Demand OM Partners © Proprietary and Confidential - p. 11 -
  • 12. Supported by only one tool… OMP Plus Next Level OMP Plus: Taking Integration To The Chain Network Design Multi- Supply Multi- Network Design Multi-Language Strategic Supply Multi-User Chain Multi- Multi-Site Inventory Optimization & Product Portfolio OptimizationModular Forecasting Inventory Optimization & Product Portfolio Optimization Forecasting Tactical Sales & Operations Planning Sales & Operations Planning In memory integration Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Operational Order Management, Order Management, Common Data Model Allocation Allocation Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling & Promising & Promising Central database Supply Manufacturing Distribution Demand OM Partners © Proprietary and Confidential - p. 12 -
  • 13. software… The OM Partners Solution: more than just software… Values Services - Visibility - Business consultancy - Agility - Implementation - Profitability - Support Services Our Solutions = Software Products + Services + Commitment Our Commitment = To make it work To keep it running OM Partners © Proprietary and Confidential - p. 13 -
  • 14. Contents The OM Partners Group - Who we are - What we do How to improve & accelerate your S&OP process with OMP Plus - S&OP? - S&OP according to OM Partners OM Partners © Proprietary and Confidential - p. 14 -
  • 15. Planning… Sales & Operations Planning….. OM Partners © Proprietary and Confidential - p. 15 -
  • 16. idea… Why S&OP ? The general idea… If supply > demand: • Rising inventories • Declining profit margins • Obsoletes •… If demand > supply: • Suffering customer service • Cost increases (overtime, premium freight, …) • Quality decrease because of rush •… Main goal of S&OP : balance supply & demand OM Partners © Proprietary and Confidential - p. 16 -
  • 17. … more in detail: S&OP definition (by Thomas Wallace) Sales and Operations Planning (S&OP) is a business process that helps companies keep demand and balance. supply in balance. It does that by focusing on aggregate volumes (product families and groups) so that mix issues (individual products and customer orders) can be handled more readily. readily. dollars, It occurs on a monthly cycle and displays information in both units and dollars, thus it integrates operational and financial planning. S&OP is crossfunctional, involving General Management, Sales, Operations, Finance and Product crossfunctional, Product Development. It occurs at multiple levels within the company, up to and including the executive in charge of the unit, business unit, e.g. division president, business unit general manager, or CEO of a smaller corporation. S&OP links the company’s Strategic Plans and Business Plan to its detailed processes – the order company’ entry, master scheduling, plant scheduling, and purchasing tools it uses to run the business on a week- week- to-week, day-to-day, and hour-to-hour basis. to- day-to- hour-to- Used properly, S&OP enables the company’s managers to view the business holistically and gives them company’ a window into the future. Source : Thomas F. Wallace, Sales & Operations Planning: The How-To Handbook 2nd edition, 2004 OM Partners © Proprietary and Confidential - p. 17 -
  • 18. S&OP: General S&OP is not only / just a planning process that balances Supply and Demand, but a management process - Involving people from sales, operations, finance,… - With a well described process description - Following a certain workflow - Requiring quite some change management in peoples thinking The S&OP process should be the missing link between - The corporate business strategy - The operational day to day planning operationalizing” A big pitfall: Beware of “operationalizing” the S&OP process Integration with these strategic and operational planning levels - Overall consensus: is important OM Partners © Proprietary and Confidential - p. 18 -
  • 19. S&OP: The process description TRADITIONAL SEQUENTIAL APPROACH Data collection and preparation: 1. Collect sales and marketing information - sales/marketing events - product life cycle 2. Develop a demand plan - statistical forecasting - current performance, … 3. Generate an unconstrained consensus forecast Demand review: - unconstrained forecast 4. Shape the demand plan for supply Supply review: - constrained plan 5. Make a constrained supply plan Financial impact calculation 6. Shape demand plan Reconciliation step / Pre-S&OP meeting: - What-if analysis 7. Review the financial impact - SWOT analysis Consensus meeting / Senior 8. Communicate the sales plan management review / Executive S&OP meeting 9. Measure and communicate the plan Communication of decisions Typically a few weeks OM Partners © Proprietary and Confidential - p. 19 -
  • 20. S&OP: The process description Although two typical approaches can be derived: - Spreadsheet/simulation approach . Flexible way to enter information . Sequential demand, supply and financial review . Trial-and-error process - Optimization approach . Demand, supply and finance should be considered simultaneously . Precise definition of scope, constraints and objective function is required consistency in S&OP process . Strategic decisions can be taken into account (modeled as constraints) OM Partners © Proprietary and Confidential - p. 20 -
  • 21. Contents The OM Partners Group - Who we are - What we do How to improve & accelerate your S&OP process with OMP Plus - S&OP? - S&OP according to OM Partners OM Partners © Proprietary and Confidential - p. 21 -
  • 22. trade- OM Partners S&OP Approach: the basic trade-offs Capacity Demand + overtime, hiring, extra machines, + marketing actions, price reductions, … subcontracting, … - premium pricing, product/customer - downtime, firing, … portfolio rationalization $ variable costs + direct fixed $ sales price costs Inventory + anticipation stock accumulation - stock build-offs $ stock holding costs Make trade-offs while maximizing value: expressed as contribution to profit, taking into account gross margin - direct fixed costs and working capital constraints OM Partners © Proprietary and Confidential - p. 22 -
  • 23. OM Partners S&OP Approach (1) OMP Plus: integrated planning levels integration between S&OP module and: - Strategic decisions - Forecasting / demand module Visibility - Operational (Master Planning and Scheduling) modules Strategic Supply Chain Network Design Supply Chain Network Design Agility Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Tactical Sales & Operations Planning Sales & Operations Planning Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Operational Order Management, Order Management, Allocation Allocation Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling & Promising & Promising Supply Manufacturing Distribution Demand OM Partners © Proprietary and Confidential - p. 23 -
  • 24. OM Partners S&OP Approach (2) The S&OP process: optimization approach - Simultaneously looking at demand, supply and finance - Including strategic business rules - While maximizing value: value based planning - Shorter planning / process cycles Profitability TRADITIONAL SEQUENTIAL APPROACH Agility 1. Collect sales and marketing information INTEGRATED OMP PLUS APPROACH 2. Develop a demand plan 1. Collect sales and marketing information 3. Generate an unconstrained consensus forecast 2. Develop a demand plan with sales prices 4. Shape the demand plan for supply 3. Generate a supply and demand plan 5. Make a constrained supply plan optimized for value Optimized for 6. Shape demand plan highest value 4. Evaluate optimized scenarios 7. Review the financial impact and reach a consensus 8. Communicate the sales plan 5. Communicate the sales plan 9. Measure and communicate the plan 6. Measure and communicate the plan Typically a few weeks Typically a few days OM Partners © Proprietary and Confidential - p. 24 -
  • 25. OM Partners S&OP approach (3): Process description S&OP preparation • Demand • Pre Pre-S&OP: Plan Supply Executive • Finance alue- value-based, integrated communication S&OP meeting • New product reconciliation & execution & process development OM Partners © Proprietary and Confidential - p. 25 -
  • 26. S&OP process description: step 1 S&OP preparation • Demand Pre Pre-S&OP: Plan • Supply Executive • Finance alue- value-based, integrated communication S&OP meeting • New product reconciliation & execution & process development OM Partners © Proprietary and Confidential - p. 26 -
  • 27. Planning Functionality: Overview Supply Chain Network Design Supply Chain Network Design Strategic Supply Chain Network Design Supply Chain Network Design Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Tactical Sales & Operations Planning Operations Planning Sales & Operations Planning Operations Planning Sales & Sales & ERP ERP & & Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning MES MES Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Operational Order Management, Order Management, Order Management, Order Management, AllocationAllocation AllocationAllocation Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling & Promising & PromisingPromising & & Promising Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling Supply Manufacturing Distribution Demand OMP FEEDBACK MANAGER OMP FEEDBACK MANAGER OM Partners © Proprietary and Confidential - p. 27 -
  • 28. Step 1a : Integrated Demand preparation Supply Chain Network Design Visibility Supply Chain Network Design Forecasting: Forecasting: Sales history Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Statistical fcst Statistical fcst Unconstrained PLC mgmt PLC mgmt forecast Promotion mgmt Promotion mgmt Sales prices Sales & Operations Planning Sales & Operations Planning ERP ERP & & MES MES Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Order Management, Order Management, Allocation Allocation & Promising & Promising Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling OMP FEEDBACK MANAGER OMP FEEDBACK MANAGER OM Partners © Proprietary and Confidential - p. 28 -
  • 29. Integrated Forecasting / S&OP View S&OP Pyramid Forecast graph of selection Year Totals Past Months Generate unconstrained S&OP forecast OM Partners © Proprietary and Confidential - p. 29 -
  • 30. Step 1b : Integrated (operational) Supply preparation Supply Chain Network Design Supply Chain Network Design Visibility Sales history Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Unconstrained forecast Sales & Operations Planning Sales & Operations Planning Sales prices -Planning Model Planning -Planning Model Planning (prod., transp., purch. and subcontr. capabilities) (prod., transp., purch. and subcontr. capabilities) ERP ERP -- Supply costs Supply costs & & MES MES Plan + stock Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Order Management, Order Management, Allocation Allocation Schedule & Promising & Promising Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling OMP FEEDBACK MANAGER OMP FEEDBACK MANAGER OM Partners © Proprietary and Confidential - p. 30 -
  • 31. Zoom in on supply planning : integrated with all planning levels Days Weeks Months S&OP MPS/deployment Scheduling OM Partners © Proprietary and Confidential - p. 31 -
  • 32. Integrated Supply / S&OP View Scheduled productions are input for S&OP cycle Month/Quarter buckets S&OP Plan line Campaign Gantt OM Partners © Proprietary and Confidential - p. 32 -
  • 33. Step 1b : Integrated (strategic) Supply preparation Supply Chain Network Design Supply Chain Network Design LT capacity & Location decisions Visibility Sales history Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Safety Stocks Unconstrained forecast Sales & Operations Planning Sales & Operations Planning Sales prices -Planning Model Planning -Planning Model Planning (prod., transp., purch. and subcontr. capabilities) (prod., transp., purch. and subcontr. capabilities) ERP ERP -- Supply costs // Sales prices Supply costs Sales prices & & MES MES Plan + stock Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Order Management, Order Management, Allocation Allocation Schedule & Promising & Promising Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling OMP FEEDBACK MANAGER OMP FEEDBACK MANAGER OM Partners © Proprietary and Confidential - p. 33 -
  • 34. Integrated Strategic balancing / S&OP View S&OP for 3 plants Demand & Supply plan for Plant A (1 Year Aggr. Bucket) Strategic Restricted Capacity for machine A1 (based on Theoretically available strategic balancing between capacity on machine A1 plants) Compared to used Used capacity on capacity on machine A1 machine A1 (95%) (104%) OM Partners © Proprietary and Confidential - p. 34 -
  • 35. S&OP process description: step 2 S&OP preparation • Demand Pre Pre-S&OP: Plan • Supply Executive • Finance alue- value-based, integrated communication S&OP meeting • New product reconciliation & execution & process development OM Partners © Proprietary and Confidential - p. 35 -
  • 36. Pre value- integrated Step 2 : Pre-S&OP: value-based, integrated reconciliation Review past performance: analyze gaps with previous plan performance: Make base scenario - Take unconstrained forecast Agility - Apply minimal supply constraints Profitability Make gap analysis - Compare base scenario with previous S&OP plan, corporate targets, … targets, trade- Make alternative demand and supply scenarios based on typical S&OP trade-offs - Derived from base scenario and gap analyses - Value- Value-based optimization of each scenario - Demand shaping - Prepare KPI view on scenarios Reconcile demand, supply and finance views - Evaluate alternative scenarios - Select key scenarios Prepare executive review OM Partners © Proprietary and Confidential - p. 36 -
  • 37. Value Based Optimization Value driver tree S&OP objective function Relationship with S&OP decisions Sales Sales (+) sales prices (+) sales prices Select the most profitable demand Contribution Contribution EBIT EBIT margin margin Variable (-) variable costs, incl. Select most cost efficient Variable (-) variable costs, incl. supply, production, costs costs non-financial stock costs non-financial stock costs transport, stocking EBIT EBIT Fixed Fixed Fixed costs directly linked (-) only direct fixed costs (-) only direct fixed costs to S&OP decisions after after costs costs Non-direct fixed costs capital capital should be left out and not costs costs converted into variable costs Working Working (-) financial stock costs (-) financial stock costs E.g. optimize stock levels, Total Total Capital Capital subject to: working capital subject to: working capital payment terms in different constraints markets, … investment investment constraints Capital Capital Permanent Permanent costs costs Investments Investments Percentage Percentage capital costs capital costs OM Partners © Proprietary and Confidential - p. 37 -
  • 38. Value based optimization Profitability Supply Chain Network Design Supply Chain Network Design LT capacity & Location decisions Sales history Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Safety Stocks Unconstrained forecast Sales prices Sales & Operations Planning Sales & Operations Planning ERP ERP & & MES MES Plan + stock Order Management, Order Management, Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Allocation Allocation & Promising & Promising Schedule Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling OMP FEEDBACK MANAGER OMP FEEDBACK MANAGER OM Partners © Proprietary and Confidential - p. 38 -
  • 39. Solver Strategies: Scenario Management Limited Capacity vs. Capacity with extra shift Base scenario Shift Base With extra shift OM Partners © Proprietary and Confidential - p. 39 -
  • 40. S&OP process description: step 3 S&OP preparation • Demand Pre Pre-S&OP: Plan • Supply Executive • Finance value-based, integrated alue- communication S&OP meeting • New product reconciliation & execution & process development OM Partners © Proprietary and Confidential - p. 40 -
  • 41. Step 3 : Executive S&OP meeting Review past performance Decision making on key scenarios Agility - Validation based on KPIs, assumptions and SWOT analysis - Tie-breaking when pre-S&OP was unable to reach consensus Tie- pre- - Check alignment with business plan / budget & corporate strategy Visibility Define action plan - Actions on gaps between plan and performance - Actions on consensus plan - What-if scenarios for evaluation in next S&OP cycles What- Who - Senior managers from supply, sales and finance - Key-users from supply, sales and finance Key- OM Partners © Proprietary and Confidential - p. 41 -
  • 42. KPI report: Scenario Management Different Scenarios KPI’ Different KPI’s Scenario Comparison chart OM Partners © Proprietary and Confidential - p. 42 -
  • 43. KPI report: Capacity report KPI’ Different KPI’s OM Partners © Proprietary and Confidential - p. 43 -
  • 44. KPI report: Service Levels and Inventory report KPI Alerts OM Partners © Proprietary and Confidential - p. 44 -
  • 45. OMP Reporter: Crystal Reports and Scenario Management OM Partners © Proprietary and Confidential - p. 45 -
  • 46. OMP Reporter : OLAP cubes OLAP Cubes - An OLAP (OnLine Analytical Processing) Cube is a data structure that allows fast and flexible analysis of data - Based on a set of predefined “measures” categorized by dimensions measures” - The tool allows to view or “pivot” the data in numerous ways pivot” OM Partners © Proprietary and Confidential - p. 46 -
  • 47. S&OP process description: step 4 S&OP preparation • Demand Pre Pre-S&OP: Plan • Supply Executive • Finance value-based, integrated alue- communication S&OP meeting • New product reconciliation & execution & process development OM Partners © Proprietary and Confidential - p. 47 -
  • 48. Step 4: Integrated communication Supply Chain Network Design Supply Chain Network Design Visibility LT capacity & Location decisions Sales history Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Safety Stocks Unconstrained forecast Sales & Operations Planning Sales & Operations Planning Sales prices Constrained Operations plan forecast SKU constrained Plan forecast ERP ERP • Sourcing + • Stock targets & & stock MES MES • Capacity decisions Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Order Management, Order Management, Allocation Allocation Schedule & Promising & Promising Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling OMP FEEDBACK MANAGER OMP FEEDBACK MANAGER OM Partners © Proprietary and Confidential - p. 48 -
  • 49. Zoom in on supply planning : integrated with all planning levels Days Weeks Months S&OP MPS/deployment Scheduling OM Partners © Proprietary and Confidential - p. 49 -
  • 50. Integrated S&OP/Supply (MPS) view S&OP view with monthly aggregated buckets and product family level MPS view with weekly buckets and product level OM Partners © Proprietary and Confidential - p. 50 -
  • 51. S&OP process description S&OP preparation • Demand Pre Pre-S&OP: Plan • Supply Executive • Finance value-based, integrated alue- communication S&OP meeting • New product reconciliation & execution & process development OM Partners © Proprietary and Confidential - p. 51 -
  • 52. S&OP with OMP Plus in a mixed vendor landscape (eg. SAP) Forecast and demand plan APO S&OP in OMP Plus DP • S&OP integrated with forecasting, planning SAP R/3 and scheduling • Consolidated, Intuitive Forecasting, Planning and Scheduling views SNP • Views including Historical Plan/Realization data Historical sales, distribution and production data • Scenario Management • Powerful End to End Optimization Engines Supply plan on finished good level PP/DS Short term supply schedule Supporting an integrated and collaborative S&OP Process • Fragmented processes OM Partners © Proprietary and Confidential - p. 52 -
  • 53. OMP Plus as an S&OP Solution: more than just software Strategic Supply Chain Network Design Supply Chain Network Design Inventory Optimization & Product Portfolio Optimization Inventory Optimization & Product Portfolio Optimization Forecasting Forecasting Tactical Sales & Operations Planning Sales & Operations Planning Supply, Manufacturing, DRP & Transport Planning Supply, Manufacturing, DRP & Transport Planning Operational Order Management, Order Management, Supply, Manufacturing, Loading & Transport Scheduling Supply, Manufacturing, Loading & Transport Scheduling Allocation Allocation & Promising & Promising Supply Manufacturing Distribution Demand Visibility Agility Profitability S&OP preparation • Demand • Supply Pre Pre-S&OP: Plan Executive • Finance value-based, integrated alue- communication S&OP meeting • New product reconciliation & execution & process development OM Partners © Proprietary and Confidential - p. 53 -
  • 54. Thank you eservaes@ompartners.com www.ompartners.com OM Partners © Proprietary and Confidential - p. 54 -