Identifying hidden inventory. Jag Shinde, Oniqua.
In many organizations maintenance function people keep their own safety stock which stores do not know about. Maintenance withdraws more inventories from the stores than the requirement at the time for the equipment repair. This is because there are times when it is hard to access the stores, e.g. night time breakdown, equipment fails at a distance from the store etc. The additional stock is stored in an easily accessible place e.g. under the desk, on the haul trucks, dozers or in small cupboards around maintenance shed or offices.
However, the larger than required withdrawals from the inventory, kicks off the replenishment system and if the inventory level goes below the ROP, a replenishment proposal is created.
The replenishment process does not check, (and is not designed to) whether the issued inventory is used or not. Such over withdrawals or over issues of inventory create a lot of unused inventory in the system. In spite of having inventory floating in the system, replenishment process is triggered.
This leads to –
• Excessive inventory in the system – part of which is unaccounted
• Incorrect movement analysis due to bulk issues
• More purchase proposals
• Increased cost of ordering
• Increased handling, admin costs
OAS could be used to identify such instances of hidden inventory. It might be achieved by comparing the issues file with the events file. Based on availability of the item usage record against events in the events file, it could be tallied with the issues file for a specific item over a time window. If the item usage record is not available in the events file, a few modifications or changes may be required to capture them.
An example would be where the issue file can indicate 100 bearings (item BR005) issued last month. It could be compared with last month’s work order history file (Events file) to identify the use of those bearings. If the Events file shows the usage of only 65 bearings (item BR005), an analyst or planner can start investigating where the remainder of 35 bearings have gone.
Such a process will lead to –
• Identifying hidden and unaccounted inventory in the system
• Identification and possible rectification of improper inventory issue and usage practice
• Accountability of usage of what is issued
• Overall keeping of the inventory system in balance
• Elimination of excess costs incurred unnecessary
I look at this as a value added advantage of OAS to clients. I look forward to your thoughts on this topic and whether this would add value to your business or help solve any business problems.
Thanks
/Jag
Written by Tony Johnston, Principal Consultant Inventory Solutions, Oniqua
Posted By Mary Badman, Business Analyst, Oniqua
It is quite common during the review process to use similar criteria when creating groups and selecting records.
You will find as you work with the OAS system, you will repeat many selections on a regular basis.
When next creating a selection or group create criteria, save the profile before completing the function… that way you can recall the criteria at any time saving you from repeating the process time and time again. It also help ensure that the same selection criteria is being used each time if comparisons of results are being made.
For example: We want to set up a group that contains all FAST records with high business impact and long lead times:
- Establish the custom selection criteria for the group
- Press the ‘Save’ button in the ‘Selection Library’
- Insert an appropriate name for the selection to clearly indicate the purpose
- Include a clear ‘Description’
- This is a personal group selection criteria which can be shared with others by simply checking the box ‘Share with other users’.
The ‘Saved Profile’ can be reused at any time and can be modified by adding, removing or editing the criteria once it has been selected for use and appears in the custom selection window.
By Jagdish Shinde, Business Analyst, Oniqua.
As part of constantly increasing our product functionality offerings, we have undertaken a mini project on improving the bill of material (BOM) functionality in the maintenance module of OAS. The aim of the project is to cater for most of the bill of material data management and data maintenance requirements that are often needed in asset intensive industries from spare part management to preventive as well as proactive maintenance point of view.
We are considering the followings to enhance the already existing BOM functionality in OAS maintenance module.
- An ability to import bill of materials from external source such as. Excel spreadsheets or access database etc, into OAS.
- Cleanse and manage the Bill of material in OAS and then export into the host systems (e.g. ERP)
- Ability to manage multilevel bill of materials (BOMs)
- Ability to display and navigate the BOMs hierarchically
- Ability to list all the equipment where the item in the given BOM is used.
- Ability to identify the business impact of a BOM item on the BOM line
- Ability to display supplier, cost, lead time information on the BOM line.
- Ability to identify whether an item is rotable, repairable, or consumable on the BOM line.
With these provisioned inclusions in the BOM functionality in OAS, it will be quiet possible manage most of the BOM management scenarios in asset intensive industries. This information will also provide an analytical edge to planner, analysts and managers to make intelligent inventory and maintenance decisions.
I am looking for further functionality requirements in addition to the list above specific to your industry and requirements. Please post your comments or thoughts to help us build better BOMs.
Thanks. Jagdish Shinde.
By Jagdish Shinde, Business Analyst, Oniqua.
I would like to gather response from Oniqua user community on the topic of service level calculation for obsolete and non stock items.
Scenario -
Currently the service levels for non stock, obsolete and no usage items (ROP/ROQ =0/0) is set to zero.
On comparisons tab when selected all, the service level for all selected items (overall service level) may be reduced from the actual value, because items with zero service level are included in the calculation.
Questions –
1. At what service level should obsolete, non stock and no usage items be defaulted to?
2. Should they included or excluded in the overall service level calculations?
Please let me know your thoughts on this.
By Jagdish Shinde, Business Analyst, Oniqua.
Due to uncertain external (or even internal) factors such as dynamic economic conditions, natural disasters, long lead time, OEM’s incapability of on time supply etc, organizations tend to stock more inventory than required in a certain time window.
An example of this practice would be stocking up fuel due to predicted price rise. The stocked diesel (or any item) may exceed the requirements of the time by many folds. This, as you all know, is called hedging the inventory, opportunistic stock piling, or war stocking (in defence systems). It can be applied to non stock items as well.
When we optimize such items in Oniqua Analytics Suite (OAS), they may be classed as overstocked or surplus.
Do you think it would be more accurate to categorise such excess stock as hedge inventory and not surplus? The reason being, as soon as OAS spots surplus, there is a recommendation to lower the stock and hence change the replenishment parameters. However, the organization may not want to do it because it has been done for a purpose.
Classing items when known beforehand as hedge inventory and excluding them from being marked as overstock/surplus would eliminate the danger of accepting the recommendation thereby leading to reduction of the stock and altering the replenishment parameters.
Currently hedge inventory items are managed in special control segment manually. They are also not identified as hedge inventory items and are always included in total inventory value calculation.
Identifying items as hedge items will paint a clear picture on total inventory value as the organization can clearly see hedge inventory value out of the total. Material departments may become alarmed by excess overall inventory value unless they can distinguish this hedge inventory.
This will help us to clearly identify the savings OAS has influenced across the range of normal items – exclusive of hedge inventory.
I see a great value in having this functionality within OAS because of the following reasons –
1. Clear identification of hedge inventory and exclusion of it from common inventory optimization routine.
2. It will help to clearly identify the savings that OAS recommendations have influenced when hedge inventory value is excluded from total inventory value in YTM, YTD snapshots.
3. Increasing adaptation of Just In Time (JIT) management of spares means no stock. However, to cater for uncertainty, material managers hedge JIT items. A hedged JIT item may not be treated in as special in control segment CS.
4. Once we incorporate into OAS the identification of hedging, we can look into scientific analytical algorithms, which will help estimate opportunities for hedging, quantities to hedge, time frame for hedge.
I would like to invite comments or suggestion from user community on this proposed functionality in OAS, as to what extent it can add value to both Oniqua Analytics Suite and your inventory management practice.
Oniqua Forecast Support Requirement
by Mason Bond, BHP Billiton Petroleum
The requirement for Oniqua to support the “Manual Forecast” which is based on a Drilling Plan or other Planned Independent Requirement is as follows.
1) Allow the user to create a “Product Group” in Oniqua which basically represents a “Well” in a Drilling Campaign [For a mine site it could be a chemical list based on a manually entered forecast value not linked to the historical data] This will allow the user to control a group of materials that are potentially different in nature yet linked due to the application of where they will be consumed.
2) Provide a simple entry screen (based on a single material number or product group) to allow the update of the forecast requirements) The existing forecast screen that is visible in Oniqua would work fine from what I can tell.
3) We will need to update the connectors to allow information manually entered in the new entry screen to flow back into SAP.
4) There is no “Mass Upload” for forecast values in SAP. They can only be entered via the forecast button in transaction MM02 or in the transaction MP30 (create) or MP31 (change) Forecast.
5) If the ability to copy an existing forecast/product group and then modify that would also potentially save the guys a lot of time as they can leverage previous experience (materials and quantities) and refine it over time. (Simulations would also be helpful)
6) A change log would also be useful (or version control) so we could look at how the forecast was entered and how it has changed (but not essential)
Call Mason Bond with any questions – +1 832 298 8888
By Murry Elton, ActewAGL
Summary is below – for more details see the User Requirements document.
Upon reviewing supplier performance there is generally a number of actions that need to be addressed by both parties. It would be of great benefit if actions could be entered as part of the review process. The output of the last performance review and its subsequent action plan should be the input to a supplier’s next review period.
• Ability to run report of review including outstanding actions.
• Ability to email review / outstanding actions to supplier.
• High level report on number of outstanding actions for suppliers by SMG.
• Action audit trail report by period. Would be used ascertain suppliers commitment to business improvement / contract performance for consideration in further business dealings.
• Outstanding ActewAGL actions to link into work queues.
Monday 9 November Salt Lake City UT USA
Tuesday 17 November Brisbane Australia
By Col Rae, Services Delivery Manager (Content), Oniqua
Oniqua Content Services is a line of business within Oniqua Pty Ltd which specialises in master data maintenance and enterprise analytics for capital intensive industries worldwide. Oniqua are the custodians and owners of what was previously the Auslang standard. This is now the Oniqua Standards Dictionary or OSD. In addition this business line handles outsourcing of analytics including inventory optimization, spend analysis, supplier performance and failure analysis
The fundamentals of getting the project planning and governance around a master data project is the basis of this paper. The rules by which we do this and the project governance are areas where you can control the output, pace and quality assurance of the data. It is essential that these control measures are in place by you, the client, to set the expectations for the vendor. Listed above are the fundamental areas to a successful master data project and we will be going through these in detail.
Most organizations at some point will question the validity and value of their master data. The danger is that it will been seen as nothing more than a ’must do’ cleanup. Good master data can and will return numerous benefits to your organization. If you are going to spend the money, make it an investment in information, knowledge and sustainability not a band-aid to a symptom of a larger underlying problem. Be sure that you select a partner to assist and guide you through the many pitfalls, providing value at every step and ensuring you get the maximum potential from the finished product without being too rigid or dictatorial about it. Standards applied need to be flexible enough to fit with your corporate guidelines and your ERP framework. You need to check the credentials of potential vendors to ensure they have a sound understanding of your ERP but also bring to the table experience gained from other ERP systems. Your vendor needs to understand how you utilize your ERP and how to adapt to your requirements without detracting from a standard, partner with you for the long term and be in an approachable position on an ongoing basis.
What I present to you is the key points to ensuring that the problem mentioned previously is treated with the attention it deserves. This is about ensuring you have a successful and sustainable solution. In order to address the problem you must first understand it, break it down and deal with the elements. We already know that the problem is the quality of the data, but have you recognised that the problem will not go away unless it is dealt with effectively. To do this you must understand your vendor and the processes they adopt in rectifying your data issues. The last thing you need is an unwieldy project that is invisible to you and over which you have little to no influence.
The presumption is that you have analysed the issues and determined that data quality is the cause. Do you have a clear picture of all the things you want the cleansed data to deliver to you, for example, do you have enough attributes to describe the item and therefore identify it, do the descriptive patterns contain sufficient information for purchasing or does the purchasing text need to be enhanced? Can you perform effective spend analysis based on category or commodity? This information ensures that you have provided sufficient information and are able to develop a specification for the cleansed data layout. Is this an inventory catalog, vendor listing, BOM, Equipment file or all of the above?
With the changes to the data structure, change management becomes an issue. As the revised data permeates through the organisation questions will arise as individuals discover that things are not as they were. How does this affect end users, purchasing officers, contract managers, inventory controllers and vendors? Will it affect reporting as classifications change? How is this going to be handled?
When spending money on a data project, what are you going to get in return? Have the invited vendors provided you with an ROI statement and are they in a position to assist you past the point of data delivery? In order to deliver an ROI statement the vendor needs to ask questions relating to the data and the issues uncovered leading to a master data project. The vendor needs to understand the issues and the potential cost ramifications of not fixing these issues.
You will have to commit resources to the project. There will be questions, guidance will be required, clarification sought, training undertaken and checks done. The levels of interaction need to be determined and names put in place. Priority needs to be placed on tasks to ensure they are done on time so as to ensure the project is done on time and on budget. Visibility of the project to key stakeholders is extremely important if momentum is to be maintained.
Be sure that your provider is willing and able to provide support both during and after the project. It maybe that we require clarification on the standard you have in place when something new is introduced. Can you call them up and ask them, can you put a face to the name and have you dealt them already?
After you have received your data you should review and audit what you have received against the original charter and specification to ensure it meets the expectations. Because data tends to be looked at as an annoyance rather an asset it tends to overlooked for pre-checks before going into production. What other asset worth possibly hundreds of thousands of dollars would you put into production without first checking to see if it is what your ordered and that is capable of doing the job intended. During the load and validation phase, preferably testing, it is advisable to have a vendor representative present to advise, attend to issues and clarify points of concern. This will go a long way to successful load on the due date therefore alleviating costing delays. Support should be visible to you via a help or support desk at company level not only at the project level to ensure it is still there after the project is completed and that tools provided to assist the upkeep are maintained on a regular basis and supported by documented processes.
A detailed project charter must be developed post sales and before work commences. This provides the opportunity for the operational arms of the organisations to meet and document precisely the expectations of both. This will clearly define the scope and the responsibilities. In contrast the specifications workshop deals with what the data will look like on completion and what format it will be delivered in. This is essential in ensuring that you get what you need and expect. The delivery schedule may be separate or part of the project plan, either way there needs to be one. You should find out as much as possible about the vendors QA processes and guarantees as well as notifying them of your expectations. A risk and issues register needs to be in place and reviewed on a regular basis with results documented in periodical reporting. No project should be closed out until the register is clear. Project completion should take place in the form of a face to face meeting to cover of on QA, issues resolution, handover of documentation and finalisation of commercial transactions. This needs to be a definitive close off of the project and the vendor needs to explain the support process in place post project. Master data projects typically fail because they do not have high level support within the organization and change management is not in place. At the time you go out for quotation ensure management know this work needs to happen. Benefits realization is dependent on internal changes that need to take place to support the outcomes. Resources must be focused on the timely delivery of data and information to the vendor to ensure the project remains on track. Yours is probably not the only project the vendor is handling and scheduling may not be all that flexible. Project governance must be a formal process. Your project manager must detail any internal processes of governance at the project start up meeting. Training is an essential element in realizing the benefits of your project. It is quite common for vendors to see the training scaled down or even cancelled with dire consequences as a result of ineffective change management practices where the value is not seen or the project not supported. Again, all of this needs to be discussed, worked out and planned for at the beginning of the project. What information is the vendor providing you with on a regular basis so you know the status of your project? Good vendors will have as part of their project management reporting processes to keep you up to date. Stay in close contact with the vendors project manager and know who to escalate problems to. Notify the vendor project manager of any changes that may impact on the project well before they happen and work with them to overcome or at least limit the fall-out. Commercial considerations impact on projects. Be aware of invoicing processes and schedules and note the payment terms as non-payment of invoices could slow or halt the project. Discuss any discrepancies with the project manager as soon as they arise. Many projects turn up tasks that were not identified in the original scope of work. Ensure that the proposal given to you covers this and that the prices are not significantly higher than those of the project tasks.
Automation tools are used to undertake tasks such as naming and to look for inconsistencies and errors in the data. Automation tools can use word recognition and differing forms of artificial intelligence along with manufacturers part number databases to consistently name items. The application of a standard is used to ensure a repeatable pattern of data structure and consistent attributes. Quality Assurance auditing relies on automation tolls and human interaction to ensure the best possible outcome.
Labor costs and an extremely competitive marketplace dictates that off-shore resources need to used. How vendors manage this process is paramount to a successful project. The project is managed by the project managers with escalation points to management. Work is scheduled by the workflow coordinator and allocated to either local, off-shore or technical resources. Work is audited for quality during and after each phase. The whole process, timeframe and detail is specified in the overarching documentation. Our project managers and quality assurance officers are our full time Australian based resources as are our lead workflow coordinators and QA officers. These people control the processes. We operate a captive team and have standing preferential contracts in place with several other teams to supply resources in peak periods. We control the processes only the project management interacts with the client.
In terms of communications you should receive from the vendor:
- Status reports on a regular basis keeping you up to date with progress and outstanding issues.
- Quality assurance reports advising you that the levels of accuracy required are being met.
You in turn should be supplying the vendor with:
- Answers to queries and clarification and rectification actions on issues
- Notice of changes to points of contact
- Any significant issues arising that may impact on the project
- Resolution to any commercial issues
The current status of the change management processes in place
Our weekly reporting keeps you up to date via a simple dashboard style report. This allow you and your management to quickly ascertain the status of your project. These reports are supported by a myriad of information and is available where applicable to the client.
You should consider early how or even if you can sustain the process of maintaining good clean data after your project. Do you have the resources who are focussed, are capable and have the time to do this? Do you have processes in place to able to effectively manage your data? Do you have a contingency plan in place if you lose your key resources either temporarily or permanently and can you ramp up during peak times? These are questions which usually do not arise as part of a project but should be considered as they provide the basis for sustainability. In addition tools specifically designed to address the issue should be considered over tools which overarch multiple like issues without specifically addressing the requirements in detail. You should look to see that you have entrenched processes preferably through workflow to ensure a consistent approach to your data maintenance.
Sustainability of data quality should not be taken lightly as it is quite often overlooked and results in a never ending succession of cleansing projects reducing the time available to analyse the data and make full use of the intelligence that can be gained from it. Do not end the process by having clean data, ensure you follow it up by extracting information from the data and putting it to good use. As in the case of data cleansing ensure you find the right vendor to assist you in this task, your return on investment will be more than worthwhile.
To ensure that you can sustain the improvements in your data you should be looking at vendors who have been around for some time and recognised as leaders in their field. They should be able to demonstrate multiple facets to their operations and a record in differing sizes and complexities of projects. The vendor should provide some background information on the experience and role of the project members along with how long they have been with the organisations role. The vendor should be placed to provide tools to assist you in maintaining the data yourself thus lowering costs. You need to be able to see a history of these tools being maintained and supported in a satisfactory manner. As for reference companies and contacts. Have you considered the standard which you intent to apply? Is it easily decipherable and can you identify the origins and experts in its application? Does the vendor supply the standard? Can their standard be cross-referenced to other standards if required? Is the vendor capable of supplying resources to you during peak periods or as a regular offering? Can the vendor assist you in getting more value out of your data through analysis, interpretation and strategic advice? What support infrastructure and processes are in place for your organization to be able to undertake recourse action if issues arise post project?
We have many resources to assist both you and us to successfully improve and maintain your data. Some of these are used internally by us, others are shared and some are designed for your use. The ones designed for your use are specific about their purpose and matched to suit various problems, scenarios and data sources.
- Plan for a known outcome via a proven process
- Ensure you can get the maximum benefit and measurable ROI
- Ensure the results achieved are sustainable and realistic
Input from Murray Elton, ActewAGL
Suggestions for members (user and partner) area on Oniqua website
- Ability to vote on user suggestions so as to prioritise
- Future developments page including timelines for implementation
- User contacts section including which ERP system they are utilising
- Did you know posts
- How to posts
- Hints and tips section
- FAQ’s section
- Getting the most of OAS system guides
- How it works section to foster greater understanding
- eLearning section
- Training videos
- Industry standard autotask examples (supplier performance, KPI’s, statistics library)
- Viewer only access to homepages to allow managers