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Manufacturing

Streamlining internal supply chain across 4 manufacturing plants and 14 warehouses spread across USA and Mexico

The client

The organization is one of the largest electrical motor manufacturs in the world, with products ranging from consumer appliance motors to large Industrial motors.

The business challenge

The client’s fractional horsepower division is spread across 4 plants and 14 warehouses in Mexico and US. This division used multiple disintegrated legacy systems for forecasting and managing processes ranging from order management to manufacturing.

The client wanted to seamlessly integrate all major internal business processes by streamlining the company’s internal supply chain, procurement, shipment and warehouse management systems. This would be followed by integration of the supply chain with the extended enterprise comprising customers and suppliers. Core processes like customer management, order entry, manufacturing and warehouse operations would also be streamlined and automated.

This initiative was intended to help achieve improved forecasting accuracy, reduced inventory turnaround time and lowreoperation costs.

The solution

We designed and developed the entire supply chain and distribution solution for forecasting, demand-supply management, warehouse management and visibility to improved collaboration with customers and suppliers.

Our expertise helped define core manufacturing and quality processes on the shop floor. Wipro consultants were involved in understanding current (as-is) operations and also in recommending future business processes (to-be).

The solution framework involved implementation of 20 modules of Oracle 11i application across functions like Forecasting & Scheduling, Quoting, Order Management, Release Management (RM)/ Electronic Data Interchange (EDI), Supply Chain, Distribution, Manufacturing, Warehouse management & Shipping, Core Manufacturing, Costing etc.)

We designed and deployed SeeBeyond middleware for EDI and real time integration to existing legacy systems. Bar coding and third party label printing systems integration was implemented to support warehouse processes like receiving, put-away and shipments. This reduced plant and warehouse operation time.

By the deployment of Demand Planning, Quoting, Order Management, EDI/RM, Supply chain planning, Distribution/logistics, financials, procurement and core manufacturing solution using Oracle 11i application suite, the client was able to streamline their entire supply chain including customers and suppliers.

We also provided a solution for a complete "configure to order" scenario through a guided selection in i-Store (Online sales module of Oracle 11i application suite) and integration of i-Store solution with Web-sphere as a pilot.

Currently the solution is live at one plant with staggered go live for the remaining in 2005.

Business benefits

	An integrated supply chain resulting in improved real time demand management, forecasting and reduced inventory levels
	Higher sales volumes due to reduction in order fulfillment and i-Store guided selling in CTO scenarios
	Improved space utilization in warehouses due to system directed and planned put-away and barcode integration
	Centralized purchasing resulted in improved supply base management and cost benefits due to consolidation
	Near real time order promising achieved through global visibility of supply-demand