Politte, Quilty Associates - Supply Chain Specialists

Education

Education Classes

There are 2 classes - Executive Overview Class and Management Overview Class.

The Agendas are identical but the Management Overview Class delves into a greater level of detail on the processes. The Executive Class is a 1 day event while the Management Class covers 3 days.

The Classes are not slide presentations. They are invariably highly interactive discussions between the instructors and class participants. This occurs primarily as a result of the fact the classes would be conducted after the initial business assessment. Therefore the instructors have an in-depth perspective on the issues and opportunities within the business. The particular business issues within the agenda items are debated and consensus is reached on definition of key process gaps and next steps to address.

Executive Class Agenda

  • Introductions, Expectations, Concerns
  • Background to Class A MRP II
  • Sales and Operations Planning (S&OP)
  • Demand Management and Forecasting
  • Supply Management
  • Implementation Process
  • Debrief and Next Steps

Management Class Agenda

  • Day 1
    •  Introductions, Expectations and Concerns
    •  Evolution of Class A MRP II
    •  Sales and Operations Planning (S&OP)
    •  Demand Management and Forecasting
    •  Supply Chain Simulation Game

  • Day 2
    •  Demand Management and Forecasting - Continued
    •  Inventory Management
    •  Distribution Resource Planning (DRP)

  • Day 3
    •  Supply Management
      •  Master Production Scheduling
      •  Plant Scheduling
      •  Capacity Planning
      •  Material Requirements Planning
      •  Supplier Scheduling
      •  Data Accuracy
    •  Continuous Improvement
    •  Project Implementation
    •  Workshop on Key Success Factors
    •  Debrief and Wrap up

 

Supply Chain Game

The Supply Chain Game has two major objectives:

  1. Provide participants with hands-on experience and insight into the implementation and operation of effective Supply Chain management processes

  2. Illustrate the benefits of applying S&OP and MRP II processes within a Continuous Improvement methodology to greatly improve performance. 

The game allows participants to gain a deeper understanding of all Supply Chain related processes and the critical need for cross functional process integration. It also helps them identify opportunities for improvement in their own area of the organization and develops confidence and energy to implement change. This is accomplished by simulating the full customer order to delivery cycle in a multi-product, multi-site manufacturing and distribution enterprise.

Participants take on roles such as Business Manager, Warehouse Manager, Operator, Materials Manager, Supplier, Customer Service Representative, Trucker or Sales Manager to manufacture and deliver 2 products in 3 SKUs to one customer. The business is composed of three operating sites: two manufacturing facilities and one warehouse. There is also a customer site and a supplier site. In addition to manufacturing at two plants, there is a packaging unit, which makes up multi-packs sold on a MTO basis with a 1-period lead-time. The supply chain is complex because:

  • The finished product from Plant A which is sold to customers from the warehouse is also used as intermediates for the product made at Plant B.
  • Plant B’s product is not only sold to the customer from the warehouse, but is also packaged as multi-packs and shipped directly to the customer.

The game consists of four rounds of orders.  Each round consists of six periods and the customer places orders for each SKU in each period. The participants have sixty seconds to fill each order (and also to fill the DRP (Distribution Resource Planning) and IPT (Inter Plant) requirements).  The product must be delivered to the customer on time and in full. Otherwise the customer refuses and returns the orders.

In round 1 the participants must decide how much of the raw materials and finished product to maintain in inventory in order to meet customer demand.  They also decide on the production schedule.  In Round 2, they try to refine their processes.  In Rounds 3 and 4, MRP II and S&OP processes are introduced.  Participants also have the opportunity to agree on and implement continuous improvements between rounds.

Success in the game is measured by two factors: Customer Service and Return on Net Assets (RONA).  Customer Service is measured by the percent of on-time deliveries.  RONA is calculated using the formula (Revenue - Costs)/Assets.  Revenue occurs only when products are delivered on time.  Costs include raw material costs, people, transportation costs, etc. Assets include inventories of raw materials and finished products, truck fleets and manufacturing facilities.

Metrics and financials are updated at the end of each round.  The game concludes with a discussion of the lessons learned.

In addition to the technical learnings; the game is quite enjoyable, people get to know each other a little better and a greater sense of teamwork is invariably achieved. It can also lead to interesting insights into the management and teamwork styles of individual players. The game requires between 18 - 30 participants and is ideally played with a cross functional team. The Game takes approximately 3 hours to play.

The vast majority of our clients use the game as the initial overview education module delivered to all employees during the project and retain it for future use in new employee orientation modules.

 

 

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