Factory Navigator

25. Oct 2018

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Factory Navigator

  1. 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
  2. Contents Market Drivers Our Approach Client Benefits References Contact Factory Navigator | A BearingPoint Accelerator
  3. 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
  4. 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
  5. 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
  6. 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.
  7. 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
  8. 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
  9. 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
  10. 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
  11. 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
  12. 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.
  13. 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.
  14. Stefan Penthin Partner BearingPoint Germany Matthias Loebich Partner BearingPoint Germany Patrick Kirchhof Manager BearingPoint Germany 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: LinkedIn: Twitter: @BearingPoint Factory Navigator | A BearingPoint Accelerator Contact © 2018 BearingPoint. All rights reserved