CMG - CONSTRAINTS MANAGEMENT GROUP - The Thoughtware People®

Proven ASR Software – Replenishment+® (R+®)

Replenishment+® is a uniquely powerful solution to the compromises and ineffectiveness of MRP in today’s manufacturing environment. It effectively facilitates pull-based materials and supply chain management throughout a manufacturing enterprise (Purchasing, Bill of Materials, and Fulfillment/Distribution). Replenishment+® is the ONLY fully ASR compliant software in the world.

To learn more about the methodology of Actively Synchronized Replenishment (ASR) download the whitepaper, Beyond MRP, here.

Web-based demonstrations are easy to schedule and take about 1 hour. If you are located outside of the United States, contact us to find an Authorized Service Provider in your area.

Through proprietary design, Replenishment+® allows users to easily MODEL, PLAN and then easily EXECUTE (View, Manage, Collaborate) through a real-time, user friendly web-based format.

ASR Modeling Attributes of Replenishment+®
ASR Planning Attributes of Replenishment+®
ASR Execution Attributes of Replenishment+®
Reporting and Trending Attributes of Replenishment+®
Schedule a Replenishment+® Web-Based Demonstration
What Customers Say About Replenishment+®
The Replenishment+® Quick Reference Solution Sheet

ASR Modeling Attributes of Replenishment+®

Easily define and manage critical part traits and buffer profiles;
Easily set seasonality adjustments for relevant parts;
Easily build and ramp up buffers over time for new product introductions or capacity/cash considerations;
Easily ramp down buffers over time for obsolete or discontinued products;
Through a breakthrough in Bill of Material functionality and design, R+® identifies key child and purchased parts for buffering that will compress lead time and reduce cash and inventory commitments while increasing service levels. The BoM explosion is de-coupled at these positions;
Powerful “what if” scenarios can allow Materials and Planning personnel to see the entire impact of different buffer positions and parts on inventory levels and dollars.

ASR Planning Attributes of Replenishment+®

Easily review and accept recommended Purchase Orders, Work/Manufacturing Orders and Transfer Orders from a user friendly Planning screen that is sorted by highly visible priority indicators;
Launch orders with due dates based on full cumulative part lead times;
Generate complete materials requirements for all purchased and manufactured parts (Replenished, Min-Max and non-buffered) tied to actual demand pull;
Automatic application of order policies for minimum/maximum/multiple order quantities;
Highly flexible Order Spike compensation settings and features allow Planners to stay on top of large Sales and Work Orders outside of the current planning horizon that will jeopardize buffer levels and service performance;
Supply Order Alerts warn Planners of CURRENT misalignments between child component supply and parent demand requirements;
Material Synchronization Alerts warn Planners of FUTURE misalignments between child component supply and parent demand requirements in order to delay work release until all necessary components are present.

ASR Execution Attributes of Replenishment+®

Simply launching Purchase Orders (POs) and Work Orders (WOs) from a more effective pull-based planning mechanism does not end the materials management challenge. These POs and WOs have to be effectively managed to synchronize with the changes that often occur within the execution horizon. Customers change their orders, quality challenges come up, there can be weather or customs related obstacles, engineering changes happen and suppliers’ capacity and reliability can temporarily fluctuate. The longer the lead times in the environment for both purchased and manufactured items the greater the synchronization execution need.

A web-based execution side makes communication, collaboration and execution throughout an organization and supply chain easy;
Clear and visible action messages for Suppliers, Buyers, Materials Managers, Manufacturing and Fulfillment personnel show them what the most immediate priorities are;
Point and click drill down allows appropriate personnel to see all order activity including all related open supply orders and all related demand allocation sources;
Projected stock out Alerts for parts where projected consumption will result in a stock out prior to receipt of incoming supply;
Inventory Alert for parts that are currently stocked out or in danger of stocking out;
Lead Time Alerts prompt personnel to check up on the status of critical non-buffered parts.
Supply Order Notes allow Materials personnel to document order status, actions and changes to stay on top of challenges within the execution horizon of specific orders;
Materials personnel can launch emails specific to certain orders right from the Execution bench;
Materials personnel can export calendar reminders specific to certain orders right from the Execution bench into their personal calendar management system (e.g. MS Outlook®).

Reporting and Trending Attributes of Replenishment+®
Replenishment+® tracks all relevant history in order to allow your organization to keep on top of improvement. R+® offers a suite of basic reports via the web including: A quick reference global dashboard Snapshot – Inventory Status – Stock Out and Stock Out with Demand (Total and by Planner) Snapshot – Inventory Status – Red Critical (Total and by Planner) Snapshot – Inventory Status – Over Top of Green Parts and Dollars (Total and by Planner) Snapshot – Number of Reds and Stock Outs (Total and by Vendor) Trending – Stock Out and Stock Out with Demand (Total and by Planner). Trending – Over Top of Green Parts and Dollars (Total and by Planner) Trending – Inventory Status by Period (Over Top of Green, Red, Yellow, Green, Out of Stock) (Total and by Planner) Trending – Number of Reds and Stock Outs (Total and by Vendor) Additionally, users can build customized snapshot and trending reports based upon your company’s unique situation, profile an informational need. Back to Top

What Customers Say About Replenishment+® “So far, I’m very impressed with the R+® software and methodology. We manage 17,500 parts (with R+®). We started to see results almost immediately. It’s provided us focus on what we need to do. Prior to it we weren’t sure we were buying the right things at the right times and now we are.” Jeff Stein, Materials Manager Erickson Air-Crane “R+® is an extremely simple product to use. It is easy to interpret the signals from the product, very visible for all levels of the company and it was simple to tell people what really needed to be done. We can already see our inventories dropping. We have not had any out of stock situations.” Craig Jolly, Production Manager Oregon Freeze Dry “The thing I like about R+® is the visibility we get with it. The ease of use; once we install it we find that people are comfortable with it very quickly. It also gives us a lot of focus on how we manage our inventories, a lot better than what we had before. We’ve seen a dramatic decrease in our stock-outs and a lot better flow in our system.” Robert Parker, Global Replenishment Project Manager LeTourneau Technologies, Inc. Back to Top

The Replenishment+® Quick Reference Solution Guide

Replenishment+® has powerful features designed to enable manufacturers to better deal with the Variability and Volatility inherent in today’s manufacturing environment as well as create a tool that dramatically increases Visibility and overall system Velocity. These four factors connect directly to the bottom line of every manufacturing enterprise.

Replenishment+® Manages Volatility and Variability; Creates Velocity and Visibility

Volatility		Dynamically Adjusting Buffers can react daily to changes in demand and supply lead time; Seasonal Adjustment Factors allow for unlimited unique seasonal profiles; Order Spike Horizon and Compensation Feature allows users to see upcoming spikes and judge the impact to all relevant buffers and adjust accordingly; Product Life Cycle Ramp Up and Ramp Down allow obsolescence to be minimized and inventory to be effectively controlled as products gain or lose market traction.

Variability		With the understanding that variability cannot be effectively managed at the individual part level, Replenishment+® looks to control the impact of variation at the systemic level; Properly placed buffers that are independently planned and managed stop the cascading effect of variation from remote distribution locations, through the entire Bill of Material and into the supply base. Alerts warn planners of potential misalignments (current and future) between child component supply and parent demand requirements.

Velocity		Cumulative lead time management and compression functionality allows the environment to adjust velocity to fit the market and cash considerations of a business; Discrete and realistic dates for all stock buffer orders combined with highly visible buffer statuses give clear indication to Manufacturing what the priorities are; Replenishment+® makes pull-based scheduling and execution easier by synchronizing materials to pull instead of using push.

Visibility		Powerful order sourcing features allow Planners to track all cumulative demand sources for all child parts Highly visible zone indicators and alerts quickly and effectively convey priorities at the planning and execution level Web-based execution module allows all points of inventory and their relative statuses across an unlimited number of sites to be actively managed from anywhere A breakthrough in BoM analysis allows planners to drill through a BoM and across BoMs to identify areas of opportunity for lead-time AND cash gains. Supply Order Alerts warn Planners of CURRENT misalignments between child component supply and parent demand requirements; Material Synchronization Alerts warn Planners of FUTURE misalignments between child component supply and parent demand requirements in order to delay work release until all necessary components are present. Lead time alerts prompt materials personnel to check status on critical non-buffered parts Supply Order Notes allow documentation of status and relevant information for specific POs and MOs within the execution horizon.

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