Factory Navigator

>FactoryNavigatorA BearingPoint Accelerator

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

ContentsMarket Drivers

Our Approach

Client Benefits

References

Contact

CLIENT BENEFITSOUR APPROACHMARKET DRIVERS REFERENCES CONTACT< >

Factory Navigator | A BearingPoint Accelerator

Market DriversThe pressure to decrease capital costs, reduce inventory and improve manufacturing and logistics processes has never been greater. E�cient 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 insu�cient 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.



Market DriversBearingPoint 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 insu�cient 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 2014)

“Now is the time for supply chain leaders to acquire a proficiency in analytics. Recent Gartner research shows that 81% of supply chain organization view analytics initiatives as a key priority for the next year.”(Gartner 2014)

“Organizations want to analyze and experiment to discover needs, expose variability, and improve performance.” (McKinsey 2013)

* Gartner 2014, “Combine Simulation and Optimization for More E�ective Supply Chain Modeling”. Gartner 2013, “Actionable Analytics“. McKinsey 2013, “Ten IT-enabled business trends for the decade ahead”

Our Approach Solve problems before they occurBearingPoint 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.



Our ApproachFields of applicationThe Factory Navigator addresses and solves logistics problems ranging from warehousing to distribution.

Warehousing• 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 bu�er size• Line-Balancing

• Flow-rate analysis• Examination of fault scenarios• Capacity planning and employee work scheduling• Secondary demand planning

Order Release and Order Scheduling

Line Supply

Production Planning

Production Control



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)

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Enterpriseoriented web

based reporting

Reporting toolsand server

Simulation andoptimization

server

Client data Dataintegration

tools

Our ApproachThe application of the Factory Navigator is based on a five phase project approach. Typical analysis cycles run in 12-14 weeks.

Weeks 1-2 Weeks 3-6 Weeks 6-9 Weeks 9-12 After Week 14

Problem DefinitionMeasure short and long-term success

Ensure continued and sustainable success

Handover to owner

Control>Implement changes

Set up monitoring and Control System

Develop Standards and Procedures

Implementation>Data source definition

Deep data diagnosis

Interface Configuration

Data Integration>Create custom analysis model

Analyze model results

Risk and cost-benefit-analysis

Recommend course of action

Solution Design>


Problem Analysis

Definition of scope

Definition of goals

Definition of KPIs


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

Baselining• Recognizing potentials• Identification of errors• Visualization • Communication

Forecasting & daily use• Alert monitor• Capacity planning • Sensitivity analysis• Bottleneck analysis• Material planning• Workforce planning

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Quantitative aspects (e.g. Demand)




Client Benefits Challenges and benefitsThe Factory Navigator is an innovative software product created for the simulation and optimization of the production and logistics processes.

Secureinvestments

Increasetransparency

Increaseperformance

Reducecost

Optimizeprocesses

Reduce risks

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 insu�cient 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.


Client Benefits In today’s competitive markets, the highest levels of quality and e�ciency are demanded from logistics processes - internally and from customers. BearingPoint satisfies these expectations with the help of the Factory Navigator.

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



ReferencesProject at a truck and bus manufacturerBearingPoint 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.




ReferencesProject at a truck and bus manufacturerDuring 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.

Challenges: • Simulation of the entire production facility.

• Integration of heterogeneous data sources.

• SAP-integration required.

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..

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.


Contact

About BearingPoint

BearingPoint consultants understand that the world of business changes constantly and that the resulting complexities demand intelligent and adaptive solutions. Our clients, whether in commercial or financial industries or in government, experience real results when they work with us. We combine industry, operational and technology skills with relevant proprietary and other assets in order to tailor solutions for each client’s individual challenges. This adaptive approach is at the heart of our culture and has led to long-standing relationships with many of the world’s leading companies and organizations. Our global consulting network of 9,700 people serves clients in more than 70 countries and engages with them for measurable results and long-lasting success. For more information, please visit: www.bearingpoint.com

© 2015 BearingPoint. All rights reserved

CLIENT BENEFITSOUR APPROACHMARKET DRIVERS REFERENCES CONTACT<

Matthias LoebichPartnerBearingPoint [email protected]

Patrick KirchhofManagerBearingPoint [email protected]

Stefan PenthinPartnerBearingPoint [email protected]


www.bearingpoint.com

mailto:[email protected]



Date post:	23-Jan-2018
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Factory Navigator

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