The bottom line shows the success …
The focus on results is always a central point of our consulting service. In this understanding we have successfully implemented numerous projects. The fact sheets below provide a first impression of content and results of our realized projects.
Optimization of Warehouse Services
Optimization of operational sequences in warehouse logistics with hazardous material
INDUSTRY:
- Service Provider Logistics
REQUIREMENTS:
- Elimination of chronic bottlenecks in personnel capacity (overtime / extra shifts)
- Avoidance of process gaps
- Elimination of ‚time wasting' procedures
- Increase of utilization of ERP system
APPROACH:
- SWOT-Analysis and subsequent definition of harmonized core processes across all subsidiaries
- Iterative transformation of process optimization
- Roll-out in additional locations
PROJECT RESULTS:
- Elimination of space-related bottlenecks through disjunction of goods entry and goods issue
- Avoidance of overtime (previously >100 hours per month per location)
- 20% decrease of average goods entry lead time
- Lead time reduction for picking through automated label printing for overpack
- Route optimization in goods entry and goods issue by 50% through XYZ classification of articles
Concept & realization of ERP system
Detailed concept with functional requirements for all core processes as part of an in-house developed ERP solution
INDUSTRY:
- Chemical toll manufacturer
REQUIREMENTS:
- Harmonization of core processes across locations
- Replacement of insufficient ERP system
- Gathering & prioritization of functional requirements
APPROACH:
- Detailed concept in alignment with all key players across all areas and locations
- Coordination of all development and test activities
- Roll-out of ERP solution in all locations
PROJECT RESULTS:
- Company-wide harmonization of core processes and master data
- Mapping of processes via all stages in order management within an integrated system
- Implementation of an IT-supported planning functionality
- Reduction of company-wide IT operation costs by approx. 50%
Concept & implementation Supplier Relationship Management
Enhancement of SRM functionality for procurement of non-merchandise goods
INDUSTRY:
- Stationary retail
REQUIREMENTS:
- Connection to operational preceding applications as well as subsequent financial accounting system
- Consistent workflow for approval including budget validation
- Streamlining of functionality for invoice verification
APPROACH:
- Preliminary study to define frame conditions and requirements of sub-processes
- Detailed concept for individual work packages
- System customizing & realization of interfaces
PROJECT RESULTS:
- Increase of transparency through bundling of purchase orders in one system
- Avoidance of budget exceedance prior to purchase order to supplier
- Automation of invoice verification (FTE reduction by approx. 15%)
- Prevention of procurement of 'unwanted' articles through optimized workflow of approval process
- Estimated potential of elimination of maverick buying', approx. 10% of procurement volume
Optimization Supply Chain processes & organization
Design of holistic Supply Chain strategy
INDUSTRY:
- Chemical industry
REQUIREMENTS:
- Reaction to cost and market pressure caused by patent discontinuation
- Development of an integrated Supply Chain strategy
- Identification, assessment and prioritization of optimization potential in processes & organization
APPROACH:
- Definition of several alternative scenarios for Supply Chain setup
- Assessment of costs and benefits for alternative scenarios
- Discussion and decision on board level
PROJECT RESULTS:
- Recommendations for action of Supply Chain setup (i.e. outsourcing of filling, packing & transportation processes at external logistic provider; intensive collaboration with distributors; implementation of decentralized Order Management)
- Identification of additional optimization potential in detailed processes (i.e. integrated planning; standardization of product packaging)
- Identified potential: 30% of total Supply Chain costs
Change Management IT Services
Change Management within global restructuring of central unit 'IT Services'
INDUSTRY:
- Logistic Provider
REQUIREMENTS:
- Global restructuring of IT area (post-merger activities including process and system harmonization) with comprehensive organizational change
- Identification of demand for end-user training
- Selection of suitable communication measures
APPROACH:
- Concept, elaboration & detailed coordination of training activities for 4.000 users in different modules
- Definition & execution of specific communication measures
PROJECT RESULTS:
- Elaboration of objectives & motivation for restructuring to gather buy-in of personnel
- Illustration of demand for change in skill set of staff
- 4.000 trained end-users in different administrative processes – on time & in budget
Process Optimization Order Fulfillment
Validation & optimization of Order Fulfillment process for the European distribution center
INDUSTRY:
- Discrete manufacturing
REQUIREMENTS:
- Analysis of optimization potential for processes and definition of to-be processes in Order Fulfillment
- Preparation for an enhanced responsibility concerning the global supply and distribution process
- Ensure handling of planned doubling of the material flow volume
APPROACH:
- Clarification of as-is processes and prerequisites
- Definition of to-be processes and derivation of demand for change
- Assessment of several alternative scenarios
- Roadmap of activities & transformation support
PROJECT RESULTS:
- Improved ATP statement through optimized quality of master data
- Increased transparency through implementation of a KPI model
- Clear definition of responsibilities to allocate possible reduction of inventory
- Implementation of a holistic approach for supplier evaluation
- Implementation of an integrated planning process for demand
Inventory Optimization via full data analysis
Fact based evaluation of logistic ERP data to optimize inventory and service level
INDUSTRY:
- Various clients
REQUIREMENTS:
- Transparent, fact-based illustration of inventory and delivery service level (based on ERP as-is data)
- Analysis of weaknesses from a process and profit perspective
- Identification of measures to optimize inventory and availability
APPROACH:
- (Automated) download of data from ERP system
- Preparation & validation of results
- Identification of optimization potential
- Conduction & prioritization of measures
PROJECT RESULTS:
- Creation of transparency & discovery of gaps & weaknesses
- Fact-based identification of optimization potential & improvement of quality of discussion
- Extensive assessment of the Supply Chain within only a few days
- Opportunity for comparison of different (business) units or locations
- Illustration of correlation and interrelation
Process optimization in material planning
Identification and transformation of optimization potential within material & production planning processes
INDUSTRY:
- Manufacturer of household appliances
REQUIREMENTS:
- Reduction of effort for material & production planning (decrease & prevention of overtime)
- Benchmarking between several planning units
APPROACH:
- Investigation of as-is situation and identification of improvement potential
- Discussion & assessment of identified potential
- Prioritization & roadmap of recommended measures
PROJECT RESULTS:
- Increase of efficiency through modification of planning parameters in SAP
- Stabilization of production planning through implementing a frozen horizon of demanded objects
- Elimination of temporary employment & reduction of overtime
- Total increase of efficiency by 20% in material & production planning
- Reduction of inventory through movement of safety stock levels towards suppliers
Interim Management SCM
Temporary execution of the management function for the Supply Chain at a toll manufacturer in the cosmetic industry
INDUSTRY:
- Toll manufacturing Cosmetics
REQUIREMENTS:
- Increase of service level
- Distinct responsibility for order management and production planning
- Establishment of a flexible planning
- Significant reduction of lead times
- Generation of transparency
APPROACH:
- To-be definition of planning processes & responsibilities
- Implementation of a planning template
- Setup of a SCM reporting with monitoring of progress
PROJECT RESULTS:
- Significant reduction of lead times for planning cycle (from 5 days to 4 hours)
- Minimization of manual planning and management effort
- Increase of delivery service level from 45% to 85%
- Identification and transformation of measures for cross-functional optimization of service level
Supply Chain Optimization & concept master planning
Overall Supply Chain optimization as well as feasibility check for global master planning
INDUSTRY:
- Chemical industry
REQUIREMENTS:
- Identification of process optimization potential
- Validation and development of global master planning function including demand and production planning
- Improvement of service level through increase of planning quality and ATP statement
APPROACH:
- Understanding of as-is situation & processes
- Derivation & validation of optimization potential
- Process definition for global master planning
- Prioritization & roadmap for measures of transformation
PROJECT RESULTS:
- Reduction of global change-over costs by 6% as well as elimination of 10% of lost sales because of capacity bottlenecks due to an improved planning quality
- Decrease of total Supply Chain costs by 1% due to an increased quality of decision making
- Additional efficiency in SC reporting (lead time from 3 days to 1 day)
- Reduction of inventory by 6% through consolidation of safety stock
Re-design of central unit 'Production & Logistics'
Re-design of central unit 'Production & Logistics' including processes, KPIs and organization
INDUSTRY:
- Discrete Manufacturing
REQUIREMENTS:
- Consolidation of logistic responsibility and definition of to-be processes based on best practices
- Definition of relevant key performance indicators (KPI)
- Elaboration of management, monitoring and reporting processes
APPROACH:
- Setup of process model (procedures & organization) for central unit 'Production & Logistics'
- Definition of causal model for process objectives and measuring
- Derivation of relevant key performance indicators
PROJECT RESULTS:
- Realignment of processes & responsibilities for 'Production & Logistics'
- Detailed KPI concept for subsequent implementation within SAP Business Intelligence (BW)
Definition of general strategies for material planning
Clustering of material groups and definition of specific norm strategies for material planning
INDUSTRY:
- Machinery & plant engineering
REQUIREMENTS:
- Determination of applicable planning strategy per material
- Ensuranc of security for assembly supply
- Ongoing identification of optimization potential in material planning (space reduction; automation, etc.)
- Reduction of procurement costs
- Standardization and data cleansing of assortment
APPROACH:
- Download of logistical data from ERP System
- Cluster analysis
- Definition of possible norm strategies
- Assignment of material to planning strategies
PROJECT RESULTS:
- Determination of clear rules and conditions of SAP settings for material planning
- Reduction of space demand through just-in-time handling (Elimination of external warehouse capacities)
- Reduction of procurement costs (transport & price) through usage of pipeline agreements
- Increase of efficiency due to usage of KANBAN strategy
- Reduction of planning effort via increased inventory for 'C' items