10/21/2013 1 S&OP’s Design, Function, and Effect at Compco Industries John Boyer and Rick Fryda • John E. Boyer, Jr., PE, CFPIM, is President of J. E. Boyer Company, a manufacturing education and consulting company founded in 1988. Additionally, his 39 years of manufacturing experience includes Rockwell International, Emerson Electric, and Weber State University. He has completed 41 S&OP projects in metal fabrication, electronics, automotive, sporting goods, and healthcare. John has a BS-IE from Lehigh University and an MBA from Utah State University. He is making his 26 th APICS International Conference presentation. John Boyer 2
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S&OP’s Design, Function, and Effect at Compco Industries...– Perform the pre-S&OP analysis. – Conduct the pre-S&OP meeting(s). – Coordinate the S&OP calendar. – Provide the
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10/21/2013
1
S&OP’s Design,
Function, and
Effect at Compco
IndustriesJohn Boyer and Rick Fryda
• John E. Boyer, Jr., PE, CFPIM, is President of J. E.
Boyer Company, a manufacturing education and
consulting company founded in 1988. Additionally,
his 39 years of manufacturing experience includes
Rockwell International, Emerson Electric, and Weber
State University. He has completed 41 S&OP projects
in metal fabrication, electronics, automotive,
sporting goods, and healthcare. John has a BS-IE
from Lehigh University and an MBA from Utah State
University. He is making his 26th APICS International
Conference presentation.
John Boyer
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Rick Fryda
• Richard C. Fryda, is President/CEO of Compco
Industries, a tankhead manufacturing company. He
has been in manufacturing for 32 years, and started
his career on the shop floor. He progressed as New
Products & Process Development Manager, Chief
Production Officer, General Manager and Chief
Operating Officer at Compco Industries before
moving into his current position as President/CEO.
Rick actively led the design and implementation of
the S&OP process and currently leads the monthly
activities.
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Agenda
� Introductions – 5
� S&OP overview – 10 (John)
� S&OP eight process steps – 10 (John)
� 10 implementation steps – 10 (John)
� Compco Industries S&OP story – 30 (Rick)
� Keys to success – 5 (John)
� Wrap-up – 5 (John and Rick)
43 Slides
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Session Objective
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Sales & Operations Planning
Demand Supply
Ordersforecast
Inventorycapacity
Top Top Top Top management’s management’s management’s management’s hhhhandle andle andle andle on the on the on the on the businessbusinessbusinessbusiness
It is the activity for effectively balancingdemand and supply on a regular and formal basis.
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Accountsreceivable
Generalledger
AccountspayableCosting
Sales orderinformation
Manufacturinginformation
Distributionand inventoryinformation
Product andengineeringinformation
Order promising and scheduling
Material planning inventory
management
Strategic planningoperating plan
budget
Sales and operations planning
Supplierpartnershipexecution
Shop floorvalue-addexecution
Business Enterprise Model
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Month endactuals
S&OP CoordinatorDay 1
Demand SupplyPerformance
Sales datasubmission
Sales PeopleDay 1
Sales dataaggregation
S&OP CoordinatorDay 1
Corporatesales review
VP SalesDay 2
Pre-S&OP analysisS&OP Coordinator
Day 3-4
Pre-S&OP meetingVP Operations
Day 4
S&OP meetingPresident
Day 5
Communicationand feedback
S&OP CoordinatorDaily - Weekly
S&OP Process Steps
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Questions for Everyone
� What did we say we were going to do (this month’s forecast)?
� What did we do (month’s actuals)?
� Why the difference (analysis)?
� What are we doing about it (action plan)?
� What are we doing moving forward (the updated forecast)?
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Who is doing the asking?
and
Who is being asked?
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SHOW UP!
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LEARN IT!
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• Responsible for providing data/information in a “fit-for-use” condition for the sales and operations planning process. Specific duties:
– Ensure that all month-end actuals are collected.
– Perform the pre-S&OP analysis.
– Conduct the pre-S&OP meeting(s).
– Coordinate the S&OP calendar.
– Provide the S&OP meeting package.
– Ensure that all players are trained in the S&OP process.
• Must have marvelous interpersonal skills, full command of the business system, detailed working knowledge of Excel, considerable knowledge of customers and products, and must know all of the players well.
• Should have an authority position reporting either to the president or a vice president.
The S&OP Coordinator
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Investigate, Assess, Educate, Decide
Calendar
S&OP Implementation Steps
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It Enables “Show Up”
S&OP Calendar
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Investigate, Assess, Educate, Decide
Calendar
Format, Definitions, Tools, Data
S&OP Implementation Steps
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Product C - S&OP - Any Company, Inc.
Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Total
Bookings Units 1050 900 825Dollars $231,000 $198,000 $181,500