Method and apparatus providing a supply chain management system useful in outsourced manufacturing

• US 20070203770A1
• Filed: 05/01/2007
• Published: 08/30/2007
• Est. Priority Date: 04/30/2001
• Status: Active Grant

• Current Assignee: Arvind Bedi, Franklin Grosvenor, John Turk, Richard Roney, Timothy Butzow
• Original Assignee: Arvind Bedi, Franklin Grosvenor, John Turk, Richard Roney, Timothy Butzow
• Inventors: Turk, John, Roney, Richard, Bedi, Arvind, Butzow, Timothy, Grosvenor, Franklin
• Granted Patent: US 7,426,478 B2
• Time in Patent Office: Days
• US Class Current: 705/7
• CPC Class Codes: G06Q 10/04 Forecasting or optimisation specially adapted for administrative or management purposes, e.g. linear programming or "cutting stock problem" market predictions or forecasting for commercial activities G06Q30/0202
• CPC Class Codes: G06Q 10/063 Operations research, analysis or management
• CPC Class Codes: G06Q 10/08 Logistics, e.g. warehousing, loading or distribution; Inventory or stock management
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders

Abstract

A method is disclosed for automatically identifying and resolving one or more discrepancies in an outsourced manufacturing supply chain in which a plurality of supply chain partners participate. According to this aspect, information representing one or more supply chain events is received from each of the supply chain partners in a database with which each of the supply chain partners may communicate over a public network. One or more rules are applied periodically to the supply chain event information, resulting in generating one or more alerts pertaining to one or more discrepancies that are found in the supply chain event information. The alerts are communicated to the supply chain partners who are participating in a transaction to which the discrepancies relate. Each alert remains active until second information is received that represents a second supply chain event that resolves the alert. According to one feature, the alerts are periodically escalated until they are resolved. A hub-and-spoke supply chain management system that facilitates the foregoing method, and other features, is also disclosed. In other aspects, the invention encompasses a computer apparatus, a computer readable medium, and a carrier wave configured to carry out the foregoing steps.

Claims

1. A method of automatically identifying and resolving one or more discrepancies in an outsourced manufacturing supply chain in which a plurality of supply chain partners participate, the method comprising the computer-implemented steps of:

communicating to a direct contract manufacturer a forecast for a product, wherein the direct contract manufacturer is a manufacturer of the product and is a supply chain partner in the plurality of supply chain partners;

receiving a master schedule and a gross demand for the product from the direct contract manufacturer;

receiving first supply chain event information representing one or more first supply chain events from three or more supply chain partners at three or more respective levels of a supply chain at a database with which each of the supply chain partners communicate over a network;

periodically applying one or more rules to the first supply chain event information, wherein the one or more rules are stored in a database;

generating one or more alerts pertaining to one or more discrepancies that are found in the supply chain event information, based on applying the rules;

communicating one of the alerts to the three or more supply chain partners at the three or more respective levels of the supply chain who are participating in a transaction to which the discrepancies relate;

receiving second information that represents a second supply chain event that resolves the alert;

resolving the alert in the database based on the second information; and

periodically escalating the alert to one or more pre-defined parties associated with each of the supply chain partners who are participating in the transaction to which the discrepancies relate, until the second information is received.

2. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying an Expected Delivery Disconnect rule to identify one or more differences between a Buy-Side Partner'"'"'s PO delivery date and quantity and a Sell-Side Partner'"'"'s Sales Order delivery date and quantity.

3. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying an Unplaced Purchase Order rule to identify planned purchase orders for which an actual purchase order has not yet been placed.

4. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Late Purchase Order Receipt rule to identify purchase orders that have late receipts to a Buy-Side Partner.

5. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Late Sales Order Shipment rule to identify sales orders having late ship dates to the Buy-Side Partner.

6. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Late Trigger Start rule to identify Work Orders having late starts to the enterprise, based on late trigger starts.

7. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Supply/Demand Disconnect rule to identify when a Partner'"'"'s Gross Component Demand exceeds its Supply over the course of the planning period.

8. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Baseline Forecast Disconnect rule to identify a difference between a baseline forecast of a Buy-Side Partner and a forecast of said partner for a current week. 9. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Forecast Time Fence Disconnect rule to identify a difference between a Current Forecast of the enterprise and a previous week forecast in comparison to a Time Fence Agreement that the enterprise has entered into with the partner.

9. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Lead Time Disconnect rule to identify one or more differences in Lead Times between a Buy-Side Partner and a Sell-Side Partner.

10. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Sales Order Change rule to identify one or more purchase orders that have changed and that will affect current Sales Orders.

11. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Top Level Demand Disconnect rule to identify one or more differences between a forecast of the enterprise and a master production schedule load of a contract manufacturer that is one of the supply chain partners.

12. The method as recited in claim 1, wherein periodically applying rules comprises the steps of applying a Lead Time/Delivery Date Disconnect rule to identify one or more purchase orders that have been placed with Lead Times different than quoted Lead Times.

13. An apparatus for automatically identifying and resolving one or more discrepancies in an outsourced manufacturing supply chain in which an enterprise and a plurality of its supply chain partners participate, comprising:

a network interface that is coupled to the data network for receiving one or more packet flows therefrom;

a processor;

one or more stored sequences of instructions which, when executed by the processor, cause the processor to carry out the steps of;

communicating to a direct contract manufacturer a forecast for a product, wherein the direct contract manufacturer is a manufacturer of the product and is a supply chain partner in the plurality of supply chain partners;

receiving a master schedule and a gross demand for the product from the direct contract manufacturer;

receiving first supply chain event information representing one or more first supply chain events from three or more supply chain partners at three or more respective levels of a supply chain at a database with which each of the supply chain partners communicate over a network;

periodically applying one or more rules to the first supply chain event information, wherein the one or more rules are stored in a database;

generating one or more alerts pertaining to one or more discrepancies that are found in the supply chain event information, based on applying the rules;

communicating one of the alerts to the three or more supply chain partners at the three or more respective levels of the supply chain who are participating in a transaction to which the discrepancies relate;

receiving second information that represents a second supply chain event that resolves the alert;

resolving the alert in the database based on the second information; and

periodically escalating the alert to one or more pre-defined parties associated with each of the supply chain partners who are participating in the transaction to which the discrepancies relate, until the second information is received.

14. The apparatus as recited in claim 13, wherein periodically applying rules comprises the steps of applying an Expected Delivery Disconnect rule to identify one or more differences between a Buy-Side Partner'"'"'s PO delivery date and quantity and a Sell-Side Partner'"'"'s Sales Order delivery date and quantity.

15. The apparatus as recited in claim 13, wherein periodically applying rules comprises the steps of applying an Unplaced Purchase Order rule to identify planned purchase orders for which an actual purchase order has not yet been placed.

16. An apparatus for automatically identifying and resolving one or more discrepancies in an outsourced manufacturing supply chain in which a plurality of supply chain partners participate, comprising:

means for communicating to a direct contract manufacturer a forecast for a product, wherein the direct contract manufacturer is a manufacturer of the product and is a supply chain partner in the plurality of supply chain partners;

means for receiving a master schedule and a gross demand for the product from the direct contract manufacturer;

means for receiving first supply chain event information representing one or more first supply chain events from three or more supply chain partners at three or more respective levels of a supply chain at a database with which each of the supply chain partners communicate over a network;

means for periodically applying one or more rules to the first supply chain event information, wherein the one or more rules are stored in a database;

means for generating one or more alerts pertaining to one or more discrepancies that are found in the supply chain event information, based on applying the rules;

means for communicating one of the alerts to the three or more supply chain partners at the three or more respective levels of the supply chain who are participating in a transaction to which the discrepancies relate;

means for receiving second information that represents a second supply chain event that resolves the alert;

means for resolving the alert in the database based on the second information; and

means for periodically escalating the alert to one or more pre-defined parties associated with each of the supply chain partners who are participating in the transaction to which the discrepancies relate, until the second information is received.

17. The apparatus as recited in claim 16, wherein periodically applying rules comprises the steps of applying an Expected Delivery Disconnect rule to identify one or more differences between a Buy-Side Partner'"'"'s PO delivery date and quantity and a Sell-Side Partner'"'"'s Sales Order delivery date and quantity.

18. A computer-readable medium carrying one or more sequences of instructions for automatically identifying and resolving one or more discrepancies in an outsourced manufacturing supply chain in which a plurality of supply chain partners participate, which instructions, when executed by one or more processors, cause the one or more processors to carry out the steps of:

communicating to a direct contract manufacturer a forecast for a product, wherein the direct contract manufacturer is a manufacturer of the product and is a supply chain partner in the plurality of supply chain partners;

receiving a master schedule and a gross demand for the product from the direct contract manufacturer;

receiving first supply chain event information representing one or more first supply chain events from three or more supply chain partners at three or more respective levels of a supply chain at a database with which each of the supply chain partners communicate over a network;

periodically applying one or more rules to the first supply chain event information, wherein the one or more rules are stored in a database;

generating one or more alerts pertaining to one or more discrepancies that are found in the supply chain event information, based on applying the rules;

communicating one of the alerts to the three or more supply chain partners at the three or more respective levels of the supply chain who are participating in a transaction to which the discrepancies relate;

receiving second information that represents a second supply chain event that resolves the alert;

resolving the alert in the database based on the second information; and

periodically escalating the alert to one or more pre-defined parties associated with each of the supply chain partners who are participating in the transaction to which the discrepancies relate, until the second information is received.

19. The medium as recited in claim 18, wherein periodically applying rules comprises the steps of applying an Expected Delivery Disconnect rule to identify one or more differences between a Buy-Side Partner'"'"'s PO delivery date and quantity and a Sell-Side Partner'"'"'s Sales Order delivery date and quantity.