Biomedical Manufacturer Plant Planning and Detailed Sequencing
Implementation of Adexa’s Plant Planner (PP) and Shop Floor Sequencer (SFS) at a medical device manufacturer with complex manufacturing routings and resource requirements including multiple machines, tooling and labor skill classes. Routing data was imported from SAP but all bills-of-resources, resource alternatives and individual resources were created and maintained in Adexa’s Master Data Management (MDM) module.
Biomedical Manufacturer Plant Planning and Detailed Sequencing
Implementation of Adexa’s Plant Planner (PP) and Shop Floor Sequencer (SFS) at a medical device manufacturer with complex manufacturing routings and resource requirements including multiple machines, tooling and labor skill classes. Routing data was imported from SAP but all bills-of-resources, resource alternatives and individual resources were created and maintained in Adexa’s Master Data Management (MDM) module.
Nutritional Products Supply Chain Planning
Optimum Profit Consulting implemented Adexa’s Supply Chain Planner (SCP) to coordinate the global movement of materials across the supply chain. Products included vitamins, minerals and supplements packaged as tablets, capsules and gelcaps.
Medical Device Manufacturing Planning and Detailed Sequencing
Optimum Profit Consulting assisted in the implementation of Adexa’s Plant Planner (PP) and Shop Floor Sequencer (SFS) for an orthopedics manufacturer. The PP coordinated the movement of parts across seven stages of manufacturing and SFS created the detailed sequence of work orders at each manufacturing operation based on the minimization of setup time and work order priority.
Latex Mattress Manufacturer Supply Chain Planning and Detailed Sequencing
Optimum Profit Consulting implemented Adexa’s Supply Chain Planner (SCP) to coordinate the global movement of materials across the supply chain. The Shop Floor Sequencer (SFS) was used to develop optimal production sequences based on product characteristics including height, width, density and foam type.
Aerospace & Defense Financial Sales & Operations Planning (S&OP)
Optimum Profit Consulting configured Kinaxis’s RapidResponse software to use the built-in Financial Sales & Operation Planning (S&OP) capabilities. The built-in capabilities include workbooks (e.g. Consensus Demand Planning), widgets (e.g. S&OP Widgets Workbook) and dashboards (e.g. S&OP Executive Dashboard) to support the monthly S&OP process using financial data.
Aerospace & Defense Sales & Operations Planning (S&OP) Automation
Optimum Profit Consulting led the implementation of Kinaxis’s RapidResponse software to automate the monthly Sales & Operations Planning (S&OP) process. Prior to the implementation all the data used for the monthly S&OP process was created in Excel and PowerPoint. During the implementation custom workbooks,dashboards and treemaps were developed in RapidResponse to display S&OP data for program lateness, material supply problems, labor and machine utilization and forecasted program demands.
Fabless Semiconductor Supply Chain Planning & Optimization
Optimum Profit Consulting led the implementation of a global supply chain planning and optimization solution to minimize total supply chain costs for a semiconductor company. The supply chain used contract manufacturers for fabrication, bump, probe, assembly and test. Adexa’s Collaborative Operation Planner (COP) was used to determine cost optimal sourcing by stage by month. The optimal sourcing ratios were used as inputs to Adexa’s Supply Chain Planner (SCP) which did the detailed resource planning for the probe and test operations. “Greybox” capacity modeling was used for planning the fabrication, bump and assembly operations.
Footwear Distribution Center Design
Optimum Profit Consulting was subcontracted to develop optimal inventory plans for a sports shoe manufacturer as part of a distribution center design project. LLamasoft’s Supply Chain Guru was used to determine the optimal location for the new distribution center. Optimum Profit Consulting’s Inventory Optimizer was used to create optimal inventory plans based on demand, demand variability, lead time, lead time variability, part class, desired service level and cost. Optimal inventory plans were developed for a variety of ten-year growth prediction to determine the overall storage space requirements for the new distribution center.
Semiconductor Capacity Planning & Order Promising
Optimum Profit Consulting provided project management and solution consulting for the implementation of Kinaxis RapidResponse software to provide global supply planning, constrained manufacturing planning and order promising. Assisted in the creation of the Conceptual Solution Design (CSD), data mapping, software configuration, user training and acceptance testing. The supply chain network included multiple manufacturing locations, contract manufacturers and distribution centers.
Nutritional Products Inventory Optimization
Optimum Profit Consulting led the implementation of multi-echelon inventory optimization and constrained capacity planning as part of an overall Sales & Operations Planning (S&OP) project. Optimal safety stock recommendations for finished goods, work-in-process and raw materials were developed to maximize customer service while minimizing inventory costs. The optimal safety stock targets were entered into SysPro and the MRP logic created the workorders and purchase orders required to maintain the optimal inventory targets.
Semiconductor Wafer Mix Optimization
Optimum Profit Consulting led the implementation of a network optimization tool to improve profitability by determining the optimal mix of wafers to start each week across nine fabrication plants for a leading semiconductor manufacturer. The project modeled the capacities for the fabrication, probe, assembly and test plants using a normalized “White Box” approach to gate the capacities on a weekly basis without the need to model every route and operation in detail. A linear program was used to calculate the optimal mix of wafers to start each week to maximize overall profitability. For weeks when there was less demand than available capacity the solver determine the optimal “fill” parts to start so that the fabrication plants were fully utilized. The model used forecasted demand, forecasted prices, transportation costs, manufacturing costs and inventory targets and solved across 52 weekly buckets.
Inventory Optimization - Industrial Distributor
Optimum Profit Consulting provided on-site consulting and Inventory Optimization software to calculate optimal inventory targets for an industrial distribution company. The project increase customer service from 76.5% to 96.5% while reducing inventory costs by 16.9%. ABC classification based on contribution margin was used to rank each item as an "A", "B" or "C" item. The customer service target for "A" items is 98.0%, for "B" items is 95.0% and for "C" items is 92.0%. Part of the project involved analyzing past demand history and lead-time history to develop the demand and lead-time means and standard deviations needed for the inventory optimization software.
Yarn Manufacturing Network Optimization
Provided the software and consulting services to determine the lowest cost way to source yarn across several plants for a leading carpet manufacturer. The Optimum Profit Consulting Strategic Network Optimization (SNO) application was used to model the network of yarn plants and produce the cost optimal way to source production. SNO uses a mixed-integer linear programming engine to calculate the optimal (lowest cost or highest profit) way to source demand, production and supplies across a company’s manufacturing and distribution network.
Provided the software and consulting services to determine the lowest cost way to source yarn across several plants for a leading carpet manufacturer. The Optimum Profit Consulting Strategic Network Optimization (SNO) application was used to model the network of yarn plants and produce the cost optimal way to source production. SNO uses a mixed-integer linear programming engine to calculate the optimal (lowest cost or highest profit) way to source demand, production and supplies across a company’s manufacturing and distribution network.
Consumer Packaged Goods Inventory Optimization
Optimum Profit Consulting provided on-site consulting to help implement Inventory Planning & Optimization at a leading CPG company. The project produced time-varying inventory targets for all locations in a hub-and-spoke distribution network that reduced overall inventories while maintaining customer service targets. Part of the project involved analyzing past demand history and lead-time history to develop the demand and lead-time means and standard deviations needed by the software.
Optimum Profit Consulting provided on-site consulting to help implement Inventory Planning & Optimization at a leading CPG company. The project produced time-varying inventory targets for all locations in a hub-and-spoke distribution network that reduced overall inventories while maintaining customer service targets. Part of the project involved analyzing past demand history and lead-time history to develop the demand and lead-time means and standard deviations needed by the software.
Building Products Network Optimization
Optimum Profit Consulting was part of the project team that implemented Manugistics Networks Strategy and Fulfillment modules for a global building products company. The model included all manufacturing, distribution and warehousing locations and was used to determine the optimal way to source production and distribution within the supply chain network at the lowest overall cost.
Optimum Profit Consulting was part of the project team that implemented Manugistics Networks Strategy and Fulfillment modules for a global building products company. The model included all manufacturing, distribution and warehousing locations and was used to determine the optimal way to source production and distribution within the supply chain network at the lowest overall cost.
SuperTug Utilization
The goal of the SuperTug Utilization project was to determine if a better dispatch method could be used to improve the utilization of the SuperTug fleet at a major United States airport. When a SuperTug isn't available but an aircraft still needs to be moved a maintenance crew can use the aircrafts jet engines for the move which burns a substantial amount of aviation fuel.
The airport has a fleet of nine SuperTugs and the move history of the previous 14,000 moves was used to calculate the trip time statistics (mean and standard deviation) to/from different areas or the airport. A simulation model was developed that would pick the closest SuperTug not currently in use for the move. The results of the simulation showed a 23% reduction in SuperTug trip times from better dispatching of the fleet and reduced the use of maintenance crews by 95%.
The goal of the SuperTug Utilization project was to determine if a better dispatch method could be used to improve the utilization of the SuperTug fleet at a major United States airport. When a SuperTug isn't available but an aircraft still needs to be moved a maintenance crew can use the aircrafts jet engines for the move which burns a substantial amount of aviation fuel.
The airport has a fleet of nine SuperTugs and the move history of the previous 14,000 moves was used to calculate the trip time statistics (mean and standard deviation) to/from different areas or the airport. A simulation model was developed that would pick the closest SuperTug not currently in use for the move. The results of the simulation showed a 23% reduction in SuperTug trip times from better dispatching of the fleet and reduced the use of maintenance crews by 95%.
