Network-based supply chain management method

• US 8,086,506 B2
• Filed: 08/17/2009
• Issued: 12/27/2011
• Est. Priority Date: 07/20/2001
• Status: Expired due to Fees

• Current Assignee: International Business Machines Corporation
• Original Assignee: International Business Machines Corporation
• Inventors: Ayala, Roberto, Murray, Michael P., Villalobos, Mauricio Alejandro
• Primary Examiner(s): Zeender, Ryan
• Assistant Examiner(s): OBEID, FAHD A
• Application Number:
  US12/542,346
• Publication Number:
  US 20090307063A1
• Time in Patent Office: 862 Days
• Field of Search: None
• US Class Current: 705/28
• CPC Class Codes: G06Q 10/06 Resources, workflows, human or project management; Enterprise or organisation planning; Enterprise or organisation modelling
• CPC Class Codes: G06Q 10/087 Inventory or stock management, e.g. order filling, procurement or balancing against orders
• CPC Class Codes: G06Q 10/0875 Itemisation or classification of parts, supplies or services, e.g. bill of materials
• CPC Class Codes: G06Q 20/203 Inventory monitoring

Abstract

An exemplary embodiment of the invention relates to a method for facilitating supply chain collaboration in a network environment, said supply chain including an enterprise and at least one supplier. The method includes generating and transmitting an unconstrained forecast to a supplier; receiving a supplier capability statement in response; and generating a constrained forecast utilizing the supplier capability statement. The constrained forecast is transmitted to the supplier which responds with a formal commitment to product a needed supply indicated in the constrained forecast. The method also includes monitoring inventory levels at a replenishment service center by a supplier based upon a formal commitment, refilling inventory items at the replenishment service center, and facilitating delivery of the inventory items to the enterprise site by transmitting a pull signal to the replenishment service center whereby inventory items are delivered in response to the pull signal.

Claims

1. A method for facilitating replenishment execution in a network environment, said supply chain including an enterprise and at least one supplier, the method comprising:

aggregating demand received, at a central server of the enterprise, from a plurality of enterprise sites associated with the enterprise, the demand comprising materials requirements;

wherein each of the plurality of enterprise sites comprises divisions that share common material requirements with divisions from others of the plurality of enterprise sites, the common material requirements for each of the divisions corresponding with a product or commodity;

generating, using a material requirement planning system (MRP) located at an enterprise site;

an unconstrained forecast to said at least one supplier, the unconstrained forecast resulting from the aggregating, the unconstrained forecast generated at a product or commodity level, wherein the unconstrained forecast represents at least one of an aggregated demand and a projected forecast received from a group scattered among the plurality of enterprise sites, and wherein the unconstrained forecast does not take into consideration any resource constraints;

transmitting the unconstrained forecast over the network to each of the suppliers that service the enterprise sites for which the unconstrained forecast is generated;

receiving, from said at least one supplier, a supplier capability statement over the network, the supplier capability statements received by the division at each of the enterprise sites from corresponding suppliers in response to the transmitting;

performing, using the central server, a squared set analysis by generating square sets and adding capacity constraints to the unconstrained forecast by imploding component data related to the unconstrained forecast and tracing the component data through a manufacturing cycle while factoring at least one of constraints and business rules, wherein square sets represent an exploded demand for the components, wherein the square sets thereby avoid generation of demand for components that will not be consumed;

based on the results of the squared set analysis, generating, using the central server, a constrained forecast using at least one supplier capability statement, wherein the constrained forecast is at least one of equal or less than the unconstrained forecast, and wherein the constrained forecast takes into consideration all resource constraints and limits the constrained forecast to most limiting constraints;

receiving, from said at least one supplier, a formal commitment to product a needed supply indicated in said constrained forecast;

transmitting the constrained forecasts to the suppliers at an enterprise site level over the network, wherein the constrained forecasts are sent to only the suppliers who provided the formal commitment;

monitoring inventory levels at a replenishment service center by said at least one supplier based upon said formal commitment;

refilling inventory items at said replenishment service center according to said formal commitment;

facilitating delivery of said inventory items to a site location for said enterprise by transmitting a pull signal to said replenishment service center; and

receiving said inventory items in response to said pull signal,

wherein a warehouse management system application monitors the inventory levels at the replenishment center, and is configured to receive a request for parts, pick the parts and deliver the parts.

2. The method of claim 1, wherein said monitoring said inventory levels at said replenishment service center includes providing said site location for said enterprise, said at least one supplier, and said replenishment service center a visibility of said inventory materials in transit.

3. The method of claim 1, wherein said monitoring said inventory levels by said at least one supplier includes maintaining a minimum supply level.

4. The method of claim 3, wherein said minimum supply level is measured in days of supply at said replenishment service center.

5. The method of claim 4, wherein said days of supply is calculated by rationalizing current units of inventory against expected consumption.

6. The method of claim 5, wherein said expected consumption represents said constrained forecast.

7. The method of claim 1, wherein said monitoring said inventory levels is performed by accessing an inventory status provided by said replenishment service center.

8. The method of claim 1, wherein said site location for said enterprise monitors said inventory levels.

9. The method of claim 1, wherein said refilling said inventory items includes:

providing an advance ship notice to said replenishment service center and said site location for said enterprise; and

updating a database to indicate when said inventory items are shipped.

10. The method of claim 1, wherein said transmitting said pull signal to said replenishment service center includes providing a pull request number to said replenishment service center requesting delivery of said inventory items, wherein a transfer order is generated at said replenishment service center in response to said pull signal.

11. The method of claim 10, wherein a goods issued document is created in response to preparing said inventory items for delivery, said goods issued document including said pull request number.

12. The method of claim 11, wherein a goods receipt is generated upon delivery of said inventory items, said goods receipt associated with said pull request number.