Parts and other consumables replenishment for in-plant subcontract units

The Client –  A global subcontracting partner to a range of industries. The client sets up subcontracting units within large factories to manage the subcontract work. 

The Challenge –  The subcontracting process involved heavy consumption of parts and other consumables and with over a thousand of such units, the replenishment process was not optimal. The client was still operating with a mix of automation and manual processes and as a result was encountering huge operational issues, suboptimal inventory management at the units as well as their central warehouse and had to constantly resort to ad hoc decisions and approvals to cover up for the gaps. 

The Solution – The solution automated everything from demand forecasting for every unit to automated approval threshold to integration with the central warehouse and dispatch and logistics. 

The key elements of the solution – 

• Demand forecasting
• Budget controls
• Approval matrix
• Exception management and approvals
• Dispatch plan to every unit
• Logistics management
• Stock management at central warehouse
• Procurement planning
• Reverse logistics
• ERP integration
• Analytics