Optimising Inventory With S&OP
0 likes25 views
This document provides an overview of Greencore's planning processes and the challenges they faced. Greencore is a leading manufacturer of convenience foods in the UK and US. They used separate planning processes for different product categories, with forecasts, supply plans, and daily schedules developed individually. This led to suboptimal inventory levels and production inefficiencies across their sites. TXT implemented an integrated end-to-end planning solution to optimize Greencore's inventory and address these challenges.
Optimising Inventory With S&OP
- 1. Greencore Case Study Optimising Inventory with S&OP Chris Chestney Solutions Architect, Greencore Group PLC Jonathan Ogg Senior Consultant, TXT e-solutions Ltd
- 2. Agenda • TXT Introduction • Case Study: Greencore • Greencore Environment and Challenges • How these were addressed with TXT
- 3. Global Specialist in ‘End-To-End’ Planning & Visibility solutions One Single Focus: Supply Chain Planning Deep expertise and focus in Food & Beverage, Consumer Packaged Goods, Manufacturing, Wholesale, Luxury, Specialty Retail and Global Brands Powerful, Easy to Use & Flexible Platform that Tailors to your Business Global Microsoft Partner Public, Steadily Growing and Profitable Develops, supplies and installs software Formed 1989 People 700+ Turnover €61.5 Customers 350+
- 4. Europe Milano, IT Head Office Barcelona, SP Bari, IT Chemnitz, DE Genova, IT Halle (Saale), DE Leicester, UK Lyon, FR Paris, FR Torino, IT Vicenza, IT Wynyard, UK Americas Toronto, CA Atlanta, USA Asia Pacific Sydney,AU Hong Kong Singapore
- 5. Our Customers are our Best Credentials Fashion & Apparel Food & Beverage Manufacturing & Distribution Retail
- 6. S&OP / IBP
- 7. TXT – Advanced Planning & Execution "TXT software combines end to end Advanced Planning & Execution; Advanced Demand & Supply Planning and Production Scheduling, with execution provided by MES, Procurement, Warehousing, Sales Processing and Process Control. This provides a complete solution for manufacturing & distribution companies." Procurement, Warehouse, Sales, Demand Planning & Trade Promotions Advanced Supply Planning Production Scheduling & MES Process Connection
- 9. 6/23/2016 9
- 10. About Greencore • A leading manufacturer of convenience food in the UK and the US • Strong market positions in the UK convenience food market across food to go, chilled prepared meals, chilled soups and sauces, ambient sauces & pickles, cakes & desserts and Yorkshire puddings • A fast growing food to go business in the US, serving both the convenience and small store channel and the grocery channel • Turnover of c.£1.3 billion • FTSE 250 listing on London Stock Exchange (GNC.L) Tier 1 supplier to retailers
- 11. Our Locations
- 12. Business Overview Food to Go • No.1 manufacturer of sandwiches • UK sites in Worksop, London (2), Northampton, Spalding & Crosby Prepared Meals • Leading manufacturer of chilled prepared meals, quiche, pasta sauce & soup • UK sites in Kiveton, Warrington, Wisbech, Bristol & Consett Grocery & Frozen Foods • No.1 manufacturer in own label cooking sauces & pickles. • A leading manufacturer of frozen Yorkshire puddings • UK sites in Selby & Leeds Cakes & Desserts • Three distinct ‘sweet’ businesses in the UK • Produces ambient cakes, chilled desserts for retail customers as well as cakes and desserts for foodservice channels • UK sites in Hull, Taunton & Evercreech USA • A fast growing food to go business in the US, serving both the convenience and small store channel and the grocery channel • Six sites in Newburyport (MA), Brockton (MA), Fredericksburg (VA), Salt Lake City (UT), Chicago (IL) and Jacksonville (FL) Ingredients & Property • Trilby Trading – a leading importer and distributor of oil and fats for food processing • Premier and United Molasses – leading importers and distributors of molasses for animal feed and industrial use in Ireland • Property – management of the Group surplus property assets
- 13. Key Customers & Brands
- 14. Original UK Planning Process Overview by Category Prepared Meals Food To Go Sauces & Soups Cakes, Desserts & Frozen Grocery Forecast ForecastForecastForecastForecast Supply Plan Supply Plan - Finite Capacity - Optimised Cost - Balanced Load Supply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Supply Plan - Finite Capacity - Optimised Cost - Balanced Load Wisbech Daily Schedule Warrington Daily Schedule Manton Wood Daily Schedule Park Royal Daily Schedule Bristol Daily Schedule Hull Daily Schedule Leeds Daily Schedule Selby Daily Schedule Campsie Blaen Twyni Daily Schedule Kiveton Daily Schedule Bow Daily Schedule Crosby Daily Schedule Forecast Supply Plan - Finite Capacity - Optimised Cost - Balanced Load Water ForecastForecast Supply PlanSupply Plan Supply Plan - MPS/MRP - Infinite Capacity - Bottleneck identification - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load
- 15. Original UK Planning Process Overview by Category Prepared Meals Food To Go Sauces & Soups Cakes, Desserts & Frozen Grocery Forecast ForecastForecastForecastForecast Supply Plan Supply Plan - Finite Capacity - Optimised Cost - Balanced Load Supply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Supply Plan - Finite Capacity - Optimised Cost - Balanced Load Wisbech Daily Schedule Warrington Daily Schedule Manton Wood Daily Schedule Park Royal Daily Schedule Bristol Daily Schedule Hull Daily Schedule Leeds Daily Schedule Selby Daily Schedule Campsie Blaen Twyni Daily Schedule Kiveton Daily Schedule Bow Daily Schedule Crosby Daily Schedule Forecast Supply Plan - Finite Capacity - Optimised Cost - Balanced Load Water ForecastForecast Supply PlanSupply Plan Supply Plan - MPS/MRP - Infinite Capacity - Bottleneck identification - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Demand Supply Production
- 16. Current UK Planning Process Overview by Category Food To Go Cakes & Desserts GroceryForecast ForecastForecast ForecastForecastForecast Forecast Forecast Forecast ForecastForecast Prepared Meals Supply Plan - MPS/MRP - Infinite Capacity - Bottleneck identification Supply PlanSupply PlanSupply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Supply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Wisbech Daily Schedule Warrington Daily Schedule Kiveton & Consett Daily Schedule Bristol Daily Schedule Manton Wood Daily Schedule Crosby Daily Schedule London (2) Daily Schedule North- ampton Daily Schedule Grocery Supply PlanSupply PlanSupply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Supply PlanSupply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Taunton Daily Schedule Evercreech Daily Schedule Hull Daily Schedule Selby Daily Schedule Leeds Daily Schedule Demand Supply Production
- 17. Current UK Planning Process Overview by Category Food To Go Cakes & Desserts GroceryForecastForecast ForecastForecast Forecast ForecastForecast Demand Supply Production Prepared Meals Supply Plan - MPS/MRP - Infinite Capacity - Bottleneck identification Wisbech Daily Schedule Warrington Daily Schedule Kiveton & Consett Daily Schedule Bristol Daily Schedule Manton Wood Daily Schedule Crosby Daily Schedule London (2) Daily Schedule North- ampton Daily Schedule Grocery Supply PlanSupply PlanSupply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Supply PlanSupply Plan - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load - MPS/MRP - Finite Capacity - Optimised Cost - Balanced Load Taunton Daily Schedule Evercreech Daily Schedule Hull Daily Schedule Selby Daily Schedule Leeds Daily Schedule Forecast Supply Plan - Weekly - Daily - Shelf Life Supply Plan - Weekly - Daily - Shelf Life Supply Plan - Weekly - Daily - Shelf Life Supply Plan - Weekly - Daily - Shelf Life Category Plan - Long term view - Infinite Capacity – what do we make where?
- 18. Greencore Grocery - Selby Forecast Supply Plan • MPS/MRP • Finite Capacity • Optimised Cost • Balanced Load Selby Daily Schedule Demand Supply Production • 2 years Demand Plan • Collaboration with Account Management Teams • Master Plan for Finished Goods & Critical Components e.g. Glass • Finite Constraints • Maximise Labour Usage cost balanced with Inventory levels • Cost optimised Cycling to drive up yields • Synchronise Production through multiple BOM levels (up to 15) • Optimal Changeovers to drive up yield • MRP Integration
- 19. Thank you – any Questions?