Factory Navigator
The Factory Navigator is an innovative simulation
and analytics software designed to improve logistics
processes and support complex decision making across
industries.
A BearingPoint Accelerator

Contents
Market Drivers
Our Approach
Client Benefits
References
Contact
Factory Navigator | A BearingPoint Accelerator

Market Drivers
The pressure to decrease capital costs, reduce inventory and improve manufacturing and logistics processes has never been greater. Efficient production and
logistics have become a crucial success factor in many industries. Not achieving cost reduction or process innovation goals means falling behind competitors.
Despite the necessity to reduce costs, logistics processes are expected to function flawlessly at minimal costs.
Many companies struggle to balance these two contradicting goals. Hidden potentials remain unidentified. As a result, these companies operate on over-
capacity and over-stock in order to safeguard their logistics performance.
Furthermore, the complexity of today’s logistics and production processes often results in insufficient process control and inadequate decision support. ERP
systems and conventional analytics software fail to create the desired transparency, nor do they contain reliable early-warning-mechanisms.
Factory Navigator | A BearingPoint Accelerator

Market Drivers
BearingPoint helps its customers to achieve logistics excellence using the in-house Factory Navigator software.
Typical challenges are:
•• Requirements to reduce logistics costs and to improve logistics performance measures
•• Process deficiencies (e.g. stock-outs) despite overcapacity and high stock levels
•• Awareness of high hidden costs but inability to identify saving potential
•• Lack of alert and early-warning-systems, no proactive problem prevention
•• High process complexity and insufficient transparency
•• Lack of substantiated decision support tools
In 2015, analytics will move to… applications that give business analysts the flexibility to define models and test them in real-time.*
*Gartner, Combine Simulation and Optimization for More Effective Supply Chain Modeling,
Noha Tohamy, 09 July 2014, last reviewed on 6 November 2015
Factory Navigator | A BearingPoint Accelerator

Solve problems before they occur
BearingPoint experts use the Factory Navigator software in order to help their customers achieve their ambitious goals. The Factory
Navigator is an innovative simulation and analytics software designed to improve logistics processes and support complex decision
making. It is capable of producing in-depth understanding through precise models that capture the client’s processes at the right level
of detail. The valuable results are used to optimize logistics processes, conduct risk assessment or reduce costs and inventory. What-if-
comparisons enable a fast and risk-free evaluation of proposed changes.
The Factory Navigator’s software architecture is unique and unrivaled in the market because it allows for automated model generation
from various data sources including SAP. Tailor-made analysis models are automatically created from company specific data using a rich
set of interfaces. As a consequence, results are precise and problem solving cycles are short and inexpensive.
Factory Navigator | A BearingPoint Accelerator
Our Approach

Fields of application
Factory Navigator | A BearingPoint Accelerator
Our Approach
Warehousing
Order Release and Order Scheduling
Line Supply
Production Planning
Production Control
•• Inventory and parameter optimization
•• Commissioning and good-receipt processes
•• Optimization of inventory allocation
•• Throughput maximization
•• Sequence planning
•• Service level maximization
•• Evaluation of line supply strategies
•• Optimization of WIP and logistics parameters
•• Early warning for stock-outs
•• Decision support and investment safeguarding concerning layout and process alternatives
•• Determination of capacity and buffer size
•• Line-Balancing
•• Flow-rate analysis
•• Examination of fault scenarios
•• Capacity planning and employee work scheduling
•• Secondary demand planning
The Factory Navigator addresses and solves logistics problems ranging from warehousing to distribution.

Factory Navigator | A BearingPoint Accelerator
Our Approach
Data Integration
•• Extensive SAP data interfaces
•• Extensive interfaces for all common data
formats
•• Data transformation processes
•• Internal data storage models
Simulation and Optimization
•• Best-of-breed simulation software
•• Add-on for fully automatic model generation
from customer data
•• Rich library of modelling elements for
manufacturing logistics
Reporting and Analysis
•• Reporting server, reporting tools and templates
•• Web based reporting
•• KPI framework
•• Full cloud integration (optional)
Client data
Data
integration
tools
Simulation and
optimization
server
Reporting tools
and server
Enterprise
oriented web
based reporting

Factory Navigator | A BearingPoint Accelerator
Our Approach
The application of the Factory Navigator is based on a five phase project approach. Typical analysis cycles run
in 12-14 weeks.
Problem Definition
Problem Analysis
Definition of scope
Definition of goals
Definition of KPIs
Data Integration
Data source definition
Deep data diagnosis
Interface Configuration
Solution Design
Create custom analysis model
Analyze model results
Risk and cost-benefit-analysis
Recommend course of action
Implementation
Implement changes
Set up monitoring and
Control System
Develop Standards and
Procedures
Control
Measure short and long-term
success
Ensure continued and
sustainable success
Handover to owner
Weeks 1-2 Weeks 3-6 Weeks 6-9 Weeks 9-12 After Week 14

Factory Navigator | A BearingPoint Accelerator
Our Approach
The Factory Navigator can be applied for baselining current systems, forecasting future performance, safeguarding
structural and process changes, and strategic design problems.
Safeguarding Sizing
•• Safeguarding structural changes
•• Safeguarding IT-implementation
•• Risk and cost avoidance
•• Validation
•• Sizing of investments
•• Parameterization
Innovation
•• Strategic planning
•• New plant / new product
•• Design of supply chains
Forecasting daily use
•• Alert monitor
•• Capacity planning
•• Sensitivity analysis
•• Bottleneck analysis
•• Material planning
•• Workforce planning
Baselining
•• Recognizing potentials
•• Identification of errors
•• Visualization
•• Communication
Quantitative aspects (e.g. Demand)
Organizationalsetupandporcesses
Current
Current
Future
Future

The Factory Navigator is an innovative software product created for the simulation and optimization of the
production and logistics processes.
Factory Navigator | A BearingPoint Accelerator
Client Benefits
Typical Challenges:
•• Uncertainty at manufacturing launches or restructuring
processes.
•• Lack of substantiated decision support tools.
•• Hidden cost saving potential.
•• Process deficiencies (e.g. stock-outs) despite overcapacity and
high stock levels.
•• Missing early warning systems and no proactive problem
prevention.
•• High process complexity and insufficient transparency.
Benefits:
•• Lowered costs and stock reductions.
•• Informed investment safeguarding and decision support.
•• Increased logistics performance and optimized logistics
processes.
•• Early warning systems, early problem detection.
•• High transparency and better understanding of the system.
•• Discovery of the roots of problems and designing
countermeasures.
Reduce risks Optimize
processes
Reduce
costs
Increase
performance
Increase
transparency
Secure
investements

In today’s competitive markets, the highest levels of quality and efficiency are demanded from logistics processes -
internally and from customers. BearingPoint satisfies these expectations with the help of the Factory Navigator.
Factory Navigator | A BearingPoint Accelerator
Client Benefits
The key benefits are:
•• Reducing logistics costs, working capital and uncovering hidden saving potential
•• Improving logistics performance
•• Optimizing logistics processes and evaluating process design decisions
•• Safeguarding structural and process design decisions or new product launches before implementation
•• Reducing operational risks by acting as an early warning and alert system for logistics processes
•• Increasing transparency of logistics processes and creating stakeholder buy in

Factory Navigator | A BearingPoint Accelerator
References
Project at a truck and bus manufacturer
BearingPoint helped a truck and bus manufacturer to improve logistics perfomance and reduce inventory holding costs by using the
Factory Navigator. The key challenge was to prevent stock-outs of the material to line supply in order to ensure uninterrupted production.
Material shortages caused by inappropriate logistical configurations were recognized and corrected before the problems occurred in the
plant. Additionally, inventory holding costs were reduced by optimizing logistics parameter configurations. By using simulations, significant
saving potentials were identified on the shop floor. In order to achieve this, BearingPoint integrated the client’s SAP system, their
operational scheduling system and the Factory Navigator.

Factory Navigator | A BearingPoint Accelerator
References
Project at a truck and bus manufacturer
During an SAP-Rollout at a truck and bus manufacturer, the Factory Navigator was used to detect and solve problems before they
occurred. Furthermore, the inventory was significantly reduced while preserving logistics performance.
Goals and Motivation:
•• Safeguarding of an SAP-Rollout by using simulation.
•• Early detection of logistics problems to guarantee a smooth
production launch.
•• Identification of cost saving potentials.
Approach:
•• Modelling of the factory and all relevant processes with the help
of the Factory Navigator.
•• Connection of Factory Navigator to SAP and further data
sources including automatic model generation.
•• Daily analysis of the logistics process and evaluation of possible
measures including automatic model generation from client
data.
Challenges:
•• Simulation of the entire production facility.
•• Integration of heterogeneous data sources.
•• SAP-integration required.
Success:
•• Significant reduction of launch problems and, in particular,
prevention of stock-outs.
•• Early detection of logistics problems and evaluation of
countermeasures.
•• Identification of cost saving potentials through uncritical
inventory reductions.

Stefan Penthin
Partner
BearingPoint Germany
stefan.penthin@bearingpoint.com
Matthias Loebich
Partner
BearingPoint Germany
matthias.loebich@bearingpoint.com
Patrick Kirchhof
Manager
BearingPoint Germany
patrick.kirchhof@bearingpoint.com
About BearingPoint
BearingPoint is an independent management and technology consultancy with
European roots and a global reach. The company operates in three units: Consulting,
Solutions and Ventures. Consulting covers the advisory business; Solutions provides
the tools for successful digital transformation, regulatory technology and advanced
analytics; Ventures drives the financing and development of start-ups. BearingPoint’s
clients include many of the world’s leading companies and organizations. The firm has
a global consulting network with more than 10,000 people and supports clients in over
75 countries, engaging with them to achieve measurable and sustainable success.
For more information, please visit:
Homepage: www.bearingpoint.com
LinkedIn: www.linkedin.com/company/bearingpoint
Twitter: @BearingPoint
Factory Navigator | A BearingPoint Accelerator
Contact
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