Beruflich Dokumente
Kultur Dokumente
Logichem Düsseldorf
Elke Servaes
Senior Consultant
How to improve & accelerate your S&OP process with OMP Plus 35 min
- S&OP?
- S&OP according to OM Partners
How to improve & accelerate your S&OP process with OMP Plus
- S&OP?
- S&OP according to OM Partners
SUPPLY
SUPPLY MANUFACTURING
MANUFACTURING DISTRIBUTION
DISTRIBUTION DEMAND
DEMAND
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
Subsidiaries
- OM Partners France - OM Partners Deutschland
- OM Partners Nederland - OM Partners USA
- OM Partners UK - OM Partners Asia
Mill Products
Corrugated and solid board, paper Metals, plastics, flooring, …
Semi Process
Chemicals, pharmaceuticals, starch, … Consumer goods, food and beverage, dairy…
dairy…
VISIBILITY
AGILITY
PROFITABILITY
Supply
Supply Chain
Chain Network
Network Design
Design
Inventory
Inventory Optimization
Optimization &
& Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Tactical
Sales
Sales &
& Operations
Operations Planning
Planning
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning
Operational
Order
Order Management,
Management,
Allocation
Allocation
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling &
& Promising
Promising
Design Multi-
Multi-Language
Strategic
Supply Multi-
Supply Chain-User
Multi
Chain Network
Network Design
Inventory Multi-
Multi-Site& Product Modular Forecasting
Inventory Optimization
Optimization & Product Portfolio
Portfolio Optimization
Optimization Forecasting
Tactical
Sales
Sales &
& Operations
Operations Planning
Planning
In memory integration
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning
Operational
Order
Order Management,
Management,
Common Data Model Allocation
Allocation
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling &
& Promising
Promising
Central database
Values Services
- Agility - Implementation
Our Commitment =
To make it work
To keep it running
How to improve & accelerate your S&OP process with OMP Plus
- S&OP?
- S&OP according to OM Partners
• Rising inventories
• Declining profit margins
• Obsoletes
•…
Sales and Operations Planning (S&OP) is a business process that helps companies keep demand and
supply in balance.
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.
It occurs on a monthly cycle and displays information in both units and dollars,
dollars, thus it integrates
operational and financial planning.
S&OP is crossfunctional,
crossfunctional, involving General Management, Sales, Operations, Finance and Product
Product
Development.
It occurs at multiple levels within the company, up to and including the executive in charge of the
business unit,
unit, e.g. division president, business unit general manager, or CEO of a smaller corporation.
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
- 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)
How to improve & accelerate your S&OP process with OMP Plus
- S&OP?
- S&OP according to OM Partners
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
Supply
Supply Chain
Chain Network
Network Design
Design Agility
Inventory
Inventory Optimization
Optimization &
& Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Tactical
Sales
Sales &
& Operations
Operations Planning
Planning
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning
Operational
Order
Order Management,
Management,
Allocation
Allocation
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling &
& Promising
Promising
9. Measure and communicate the plan 6. Measure and communicate the plan
S&OP preparation
• Demand
Pre
Pre-S&OP: Plan
• Supply Executive
• Finance value-
alue-based, integrated communication
S&OP meeting
• New product reconciliation & execution
& process
development
S&OP preparation
• Demand
Pre
Pre-S&OP: Plan
• Supply Executive
• Finance value-
alue-based, integrated communication
S&OP meeting
• New product reconciliation & execution
& process
development
Supply
Supply Chain
Chain Network
Network Design
Design
Strategic
Supply
Supply Chain
Chain Network
Network Design
Design
Inventory
Inventory Optimization
Optimization && Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Inventory
Inventory Optimization &
Optimization & Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Tactical
Sales
Sales &
& Operations
Operations Planning
Planning
Sales
Sales &
& Operations
Operations Planning
Planning
ERP
ERP
&
&
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning MES
MES
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning
Operational
Order Order
Order Management,
Management,
Order Management,
Management,
Allocation
AllocationAllocation
Allocation
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling & && Promising
Promising
& Promising
Promising
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling
Supply Manufacturing Distribution Demand
OMP
OMP FEEDBACK
FEEDBACK MANAGER
MANAGER
OM Partners © Proprietary and Confidential - p. 27 -
Step 1a : Integrated Demand preparation
Supply
Supply Chain
Chain Network
Network Design
Design
Visibility
Forecasting:
Forecasting: Sales
history
Inventory
Inventory Optimization
Optimization &
& Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Statistical
Statistical fcst
fcst
Unconstrained PLC
PLC mgmt
mgmt
forecast Promotion
Promotion mgmt
mgmt
Sales prices
Sales
Sales &
& Operations
Operations Planning
Planning
ERP
ERP
&
&
MES
MES
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning Order
Order Management,
Management,
Allocation
Allocation
&
& Promising
Promising
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling
OMP
OMP FEEDBACK
FEEDBACK MANAGER
MANAGER
OM Partners © Proprietary and Confidential - p. 28 -
Integrated Forecasting / S&OP View
Year Totals
Past Months Generate unconstrained
S&OP forecast
Supply
Supply Chain
Chain Network
Network Design
Design
Visibility Sales
history
Inventory
Inventory Optimization
Optimization &
& Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Unconstrained
forecast
Sales
Sales &
& Operations
Operations Planning
Planning
Sales prices
-Planning
Planning
Planning Model
-Planning Model
(prod.,
(prod., transp.,
transp., purch.
purch. and
and subcontr.
subcontr. capabilities)
capabilities) ERP
ERP
-- Supply costs
Supply costs
&
&
MES
MES
Plan + stock
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning Order
Order Management,
Management,
Allocation
Allocation
Schedule &
& Promising
Promising
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling
OMP
OMP FEEDBACK
FEEDBACK MANAGER
MANAGER
OM Partners © Proprietary and Confidential - p. 30 -
Zoom in on supply planning : integrated with all planning levels
S&OP
MPS/deployment
Scheduling
Campaign Gantt
Supply Chain
Supply Chain Network
Network Design
Design
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning Order
Order Management,
Management,
Allocation
Allocation
Schedule &
& Promising
Promising
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling
OMP
OMP FEEDBACK
FEEDBACK MANAGER
MANAGER
OM Partners © Proprietary and Confidential - p. 33 -
Integrated Strategic balancing / S&OP View
Compared to used
Used capacity on capacity on machine A1
machine A1 (95%) (104%)
S&OP preparation
• Demand
Pre
Pre-S&OP: Plan
• Supply Executive
• Finance value-
alue-based, integrated communication
S&OP meeting
• New product reconciliation & execution
& process
development
Profitability
Make gap analysis
- Compare base scenario with previous S&OP plan, corporate targets,
targets, …
Make alternative demand and supply scenarios based on typical S&OP trade-
trade-offs
- Derived from base scenario and gap analyses
- Value-
Value-based optimization of each scenario
- Demand shaping
- Prepare KPI view on scenarios
EBIT
EBIT Fixed Fixed costs directly linked
Fixed (-)
after (-) only
only direct
direct fixed
fixed costs
costs to S&OP decisions
after costs
costs Non-direct fixed costs
capital
capital should be left out and not
costs
costs converted into variable
costs
Working
Working (-)
(-) financial
financial stock
stock costs
costs E.g. optimize stock levels,
Total
Total Capital
Capital subject
subject to:
to: working
working capital
capital payment terms in different
constraints markets, …
investment
investment constraints
Capital
Capital Permanent
Permanent
costs
costs Investments
Investments
Percentage
Percentage
capital
capital costs
costs
Profitability
Supply
Supply Chain
Chain Network
Network Design
Design
Sales
Sales &
& Operations
Operations Planning
Planning
ERP
ERP
&
&
MES
MES
Plan + stock
Order
Order Management,
Management,
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning Allocation
Allocation
&
& Promising
Promising
Schedule
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling
OMP
OMP FEEDBACK
FEEDBACK MANAGER
MANAGER
OM Partners © Proprietary and Confidential - p. 38 -
Solver Strategies: Scenario Management
Shift Base
S&OP preparation
• Demand
Pre
Pre-S&OP: Plan
• Supply Executive
• Finance value-
alue-based, integrated communication
S&OP meeting
• New product reconciliation & execution
& process
development
Who
- Senior managers from supply, sales and finance
- Key-
Key-users from supply, sales and finance
Different Scenarios
Different KPI’
KPI’s
Scenario
Comparison chart
Different KPI’
KPI’s
KPI Alerts
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”
measures” categorized by dimensions
- The tool allows to view or “pivot”
pivot” the data in numerous ways
S&OP preparation
• Demand
Pre
Pre-S&OP: Plan
• Supply Executive
• Finance value-
alue-based, integrated communication
S&OP meeting
• New product reconciliation & execution
& process
development
Supply
Supply Chain
Chain Network
Network Design
Design Visibility
LT capacity & Location decisions Sales
history
Inventory
Inventory Optimization
Optimization &
& Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Safety Stocks Unconstrained
forecast
Sales
Sales &
& Operations
Operations Planning
Planning Sales prices
Constrained
Operations plan forecast SKU constrained
Plan forecast ERP
ERP
• Sourcing
+ • Stock targets
&
&
stock MES
MES
• Capacity decisions
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP &
& Transport
Transport Planning
Planning Order
Order Management,
Management,
Allocation
Allocation
Schedule &
& Promising
Promising
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading &
& Transport
Transport Scheduling
Scheduling
OMP
OMP FEEDBACK
FEEDBACK MANAGER
MANAGER
OM Partners © Proprietary and Confidential - p. 48 -
Zoom in on supply planning : integrated with all planning levels
S&OP
MPS/deployment
Scheduling
S&OP preparation
• Demand
Pre
Pre-S&OP: Plan
• Supply Executive
• Finance value-
alue-based, integrated communication
S&OP meeting
• New product reconciliation & execution
& process
development
PP/DS
Short term supply schedule Supporting an integrated and
collaborative S&OP Process
• Fragmented processes
Strategic
Supply
Supply Chain
Chain Network
Network Design
Design
Inventory
Inventory Optimization
Optimization && Product
Product Portfolio
Portfolio Optimization
Optimization Forecasting
Forecasting
Tactical
Sales
Sales && Operations
Operations Planning
Planning
Supply,
Supply, Manufacturing,
Manufacturing, DRP
DRP && Transport
Transport Planning
Planning
Operational
Order
Order Management,
Management,
Supply,
Supply, Manufacturing,
Manufacturing, Loading
Loading && Transport
Transport Scheduling
Scheduling Allocation
Allocation
&& Promising
Promising
eservaes@ompartners.com
www.ompartners.com