Infosys’ blog on industry solutions, trends, business process transformation and global implementation in Oracle.

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April 28, 2009

An Insight into the Business Intelligence Needs of a Telecoms Operator

Telecoms and Media is possibly a very unique space where the customer is latched on with the service provider on an almost 24/7 basis by using its services, offerings and products. With this behavior the customer actually provides a pool of information about his day to day life, the people he maintains contacts with, the places he visits and the contents he loves getting entertained with. With this amount of detail a Telco operator can actually create a near perfect profile of all its customers using the network. I would want to believe that this amount of customer information is possibly not available with any other service or product provider in any other industry vertical. If there is I would like to hear about it

Well then with this depth of information it should be fairly easy to work on and keep the telco customers happy, right? Well as much as I would want to believe that it should be fairly easy, it is not so. Today the telecom players face a huge set of challenges with Operational efficiencies, network stability, service offerings, revenue leakage, customer satisfaction and above all churn and Average Revenue Per User (ARPU) Management. And BI plays a very key role in helping to address many of these issues and problems.

The Telecom and Media market in the last few years has undergone a silent revolution in terms of network convergence i.e. using a single network to deliver voice, data and content services. Now you have a single service provider catering to your landline needs, Internet needs, mobility needs, Television and Entertainment needs. This is a revolution which has happened over the last half a decade and the entire world over. So when we talk about a Telco operator today, chances are that it would be providing most of these services to its end customers.
The Business Intelligence and Reporting needs for a Telco could primarily be classified as A).Operational and B).Strategic or Predictive needs.
As far as the Operational BI needs are concerned we can see a good mix of needs between the both the OSS and the BSS stack. While the Network teams in the Telco might be keener on understanding the network usage and utilization, Quality of Service (QoS) KPIs, SLA adherence especially for the high valued corporate customers and above all the Inventory utilization. Networking inventory forecasting and utilization continues to be by far a very challenging subject for many Telco operators and although some packaged solutions do exist but a lot is still to be done. These metrics and KPIs are very critical and any Telco operator should have this pulse because for all the rich content and value added services that it might provide, relatively poor or inferior network coverage can pull it all down.
Also quite operational in nature are the needs of the various Product and CRM managers of Telecoms operators who wish to track the Order Processing, Service Request Processing lead times, success rates along with the call resolution satisfaction rates and efficiency scores. In order to keep your operational costs down it would make all the sense to be able to provide as many resolutions remotely without having to do a ‘truck roll’. Truck rolls or where a technician needs to visit a site in order to fix a complaint are usually an expensive affair and best avoided. There are various other similar parameters which a CRM manager would wish to monitor in order to ensure efficient and a functional support staff.
I would be doing injustice if I do not mention the biggest of them all and that is Revenue Leakage Management. It is possibly any telco player’s nightmare and a huge area to improve your bottom line. A study done a few years back, said that annual revenue loss due to revenue leakage for all major telco of the world  put together runs into around 40-50 billion USD. The reasons for revenue leakage are many and occur at different junctures of the OSS stack and also at the inter-operator connect. Any telco would be looking for the need of a robust intelligence system to identify and address this issue.
While I believe that the Operational side of telecom BI are more or less figured out  today and is more of the science, it this strategic or predictive  BI needs which is the art and is often the more difficult to crack. In my interaction with various product managers of several telcos across continents, I have learnt that the top two things he/she grapples with are “Churn” and “ARPU”. ‘Lower Churn and increase ARPU and you are there’ - that is what the Telecoms CEO tells his/her product managers. Easier said than done!  Especially in the Western European market which is possibly the most matured, advanced and above all a completely saturated segment, Telcos are facing the most daunting task of holding on to their existing customers, waging a price war and at the same time expecting to improve the top line revenues.
BI to the rescue? Well yes and no.
Calculating and Predicting churn is done by different operators in their own little way and also there are no fixed set of rules to either report or predict the churn. Although calculating the churn can be fairly standardized, predicting it is done based on different algorithms and even use of artificial intelligence. There are some standard packages available in the market which helps you identify and work on churn predictions. But at the end of the day these packages or systems are all sort of a data mining tool which sits on top an Enterprise Datawarehouse where a churn probability score is provided to all the subscribers or customers based on how the telco perceives end user behavior. The churn score is calculated based on social and behavioral algorithms. For example if a subscriber reduces his calls by more than 60% in one particular month his probability of churning increases. Or for example if the subscriber makes most of his calls to the competition’s network he is as well more likely to churn. There could be many more such parameters based on which the churn model works and there are numerous white papers and thesis which provide inputs on churn prediction.
ARPU on the other hand is again stimulated by customer’s call and products usage. Product managers typically study the usage patterns (based on various analytical exercises that get carried out) of the high valued customers and design specific marketing campaigns to stimulate usage.
Although there are many algorithms and packages to help the Telecom players to manage these two “devils” but it being an art, has still not been perfected and with changing times and human behavior needs to be revisited and remodeled constantly. That is possibly where the beauty lies!

 

Product Data Integration Challenge: Structured Vs Unstructured Data

The two key components of Master Data Management (MDM) are Product Data Management and Customer Data Management.  The customer data consists of mostly structured data like Name, Address etc., whereas product data is highly unstructured. Product Data will have unstructured data like CAD Drawings, Specification Sheets, Images etc.  While creating a product master data in a MDM system – you need to migrate product information from multiple disparate systems into your MDM system. Integration of unstructured product data during migration throws lot of challenges.

Usually the data needs to migrated into the master are maintained in different unconnected sources. Each department maintains and updated data relevant for them & fails to update the data not maintained by them. This often results in disparate data between systems.

In recent times, companies realize the need for a centralized blended record that acts as a single source of truth for their customers and products to improve their profitability and enable cross selling. This need is addressed by Master Data Management (MDM) tools. But the problem still lies in the integration of data from different legacy systems into one common MDM Data Hub. There is a need to check the quality of data from disparate systems, eliminate duplicates and blend the data to have a clean data that acts as the single source of truth and complete in all aspects. Also companies need to integrate record volumes of data in the shortest possible time.

 The traditional tools available for Data Integration (DI) – for mass volume & complex integration scenarios, and Data Quality (DQ) will work for customer data & not for product data. The reasons being; product data is not as predictable as customer data and product data is loaded with highly unstructured data. Some of the product specific data could be mentioned in their own jargon which cannot be understood by others. Also most of product MDM tools use ‘pattern’ based recognition of Inbound data, which again will be useful only for structured data.

The solution for handling unstructured data is addressed by ‘semantic’ recognition of Inbound data (i.e.) the tool should focus on the meaning not the patterns. The system should understand the variations in word-order, punctuation, spelling and character-level parsing. Also the system should continuously learn on the fly to develop its intelligence as it migrates more and more data.

One such system that is recommended by Oracle for ensuring Data Quality of Inbound data into its Product Information System is, Silvercreek’s DataLensTM system. It can map incoming product data into internal product catalog, using ‘natural language processing’ to automatically categorize products and their attributes. For companies with huge product catalogs, such as ecommerce, manufacturing, retail, CPG etc., automation of Product Data integration enables users to process thousands of records of product data with accuracy and minimal human intervention.

April 20, 2009

SOA based approach - The answer to Telco woes?

Communication service providers have and will always look for one key OSS/BSS theme "A OSS/BSS solution which is modular, flexible , low cost, faster time to market and simple to use” to increase their competitiveness in the market . The ways and means to achieve to OSS/BSS theme has evolved over many years, and the latest approach is to implement a SOA based OSS/BSS stack and the key challenge for the IT service providers is to implement a readymade OSS/BSS SOA solution at a lower cost in a shorter time frame without compromising the modularity of the architecture.

Unfortunately implementing a best in class system is not the final magic bullet to reach the end state of SOA enablement of OSS and BSS, it starts with the re engineering of processes and the mind set of people handling theses processes and to become a truly convergent service provider and to be able to offer anyservice-anytime-anywhere, SOA based architecture enablement has to be driven Top-Down and Bottom-UP.

Is enabling modular architecture the "final solution" for all of the challenges faced by Telcos ?, the answer is NO. Implementing a modular convergent architecture is the most important step for a fully convergent Telco. The biggest challenge is to define "what" and "how" to enable modular architecture, because implementation of SOA based architecture can lead to huge cost over runs and complexity mainly due to the migration from legacy to new solution. Increasingly Telco are finding ways to shorten the lead time using packaged SOA applications, which is tightly integrated , simpler to implement and yet modular.

If Telcos need to sustain their existence and competitiveness then Telcos have to find answers for the two critical questions "Is there a pre packaged SOA solution for OSS and BSS stack?" and "Does SOA based OSS/BSS solution also transform the business process and the mindset of people?"

Periodic Average Costing (PAC) Demystified

Last week when I was talking to some people, there was a major hue and cry about the need for changing the costing method. They went to the extent of trying to compare Periodic Average Costing and Average Costing. But what they failed to realize was that they were comparing apples with oranges.

Periodic Average Costing is required by law in some countries like Brazil and is applicable for fiscal inventory reporting requirement. It is invoice based and allows including additional invoiced charges in the cost of the item and hence helps report actual cost or total acquisition cost of an item at end of fiscal period.

 

Typically, Periodic Costing is shared across Inventory Orgs each of which having its own perpetual costing methods like Standard Costing, Average Costing, LIFO and FIFO. PAC operates at a Cost Group Level and not at Inventory Org Level.

 

Companies will continue to use Standard Cost at Inventory Org Level for say, Brazil while the Periodic average Cost Group will be defined to include only the Brazil Inventory Org.

 

For illustration purpose,

 

Suppose we have an Item ‘A’ in Inventory Org ‘Sao Paolo, Brazil’

Standard Frozen Cost for Item ‘A’ = USD 200

Purchase Order of 200 Units @ USD 250 received on Day 1

Purchase Order of 300 Units @ USD 300 received on Day 2

Freight = USD 400

 

Acquisition Cost (Cost incurred in acquiring the item) without using Periodic

Average Cost = USD 200 (Standard Cost)

 

Acquisition Cost using Periodic Average Cost

= USD 280.8 (200*250 + 300*300 + 400)/ (200 + 300)

 

So we are still using Standard Costing (and not changing the Costing Method) but for Fiscal Reporting, we are using the correct acquisition cost.

 

Oracle has a full-fledged PAC module with add-on BR-PAC for Brazil. BR-PAC is integrated with Integrated Receiving (RI) which was covered in one of my earlier blogs.

Unleashing MEA's Potential in Telecom Services

The telecommunication market in Middle East and Africa (MEA) is extremely diversified in nature. The region spans across 60+ countries and has an interesting mix of demand, expectations and maturity levels. In current global economy downturn, the MEA telecom market is relatively less impacted. Within some African countries the market is gaining momentum. Privatization and liberalization are visible latest trends and cost effective communication technologies are now becoming available to meet the needs of these diverse group of countries. These new technologies include fixed wireless access, mobile telephony, fiber optics and satellite.
The MEA market is dominated by two types of organizations viz. the conventional national carriers (Govt. owned entities) who are already established players and then the challengers who are generally tend to enter as second/third operators. Some of such leading operators are group companies that have spread their presence in multiple countries. They include MTN, Etisalat, Orascom, Saudi Telecom, Qtel and Zain. Several countries are opening up and offering new licenses, thus creating investment opportunities and making market more competitive.
 
In terms of technology and services, Broadband services will represent the key growth area during the next few years. In African countries, CDMA technology is also gaining popularity owning to lower costs. The existing operators are gearing up to position themselves to take advantage of this growth. The operators are keen to expand, but they must not lose sight of the importance of their established operations and how to best exploit opportunities in emerging markets.  

The awareness and importance of better service levels is growing. Consumers are expecting quick response, accurate information and faster resolution to their service issues. These expectations are driving operators to embrace state of the art business applications. Sophisticated CRM, advanced mediation and converged billing are amongst such applications. An integrated technology stack to cover entire OSS/BSS requirements is also been observed as one of the trends. Such requirements from telecom operators are providing opportunities for leading software product vendors and system integrators. Are such opportunities explored? Are global System integrators ready to take it on? 

April 17, 2009

Retail Order Management - Emerging Trends

Economists continue to come up with new theories around recovery, some talk about an L shaped recovery and off late some are suggesting a V shaped one. One thing that is emerging clearly in this economic climate is the distinct presence of Internet in Retail Sales. The traditional mall based sales in US have seen a decline in the recent years and e-commerce a catch phrase of the 90s is begining to show its effect on the Retail Sales. I focus on some interesting emerging trends in Order Management seen across Retailers who are mixing the power of the internet with the spread of their physical stores.

Consumers have increasingly taken to internet for their discretionary spending and with Retailers putting a lot of dollars into integrating online channels with their store management systems, there is an emergance of some new order management trends.

1. Channel Integration

Traditional model of merchandise delivery has been through distributor warehouses or delivery centers closer to the mall based sales channels. With an increasing presence in online sales, the traditional model saw some challenges as this required presence across a wider geography. Some retailers served the internet sales separately and that inventory was maintained differently. However with the net sales showing increasing growth in the online sector, retailers are integrating the delivery channels.

2. New Sales and Delivery Channels - Buy Online, pick or hold at the physical store, Kiosks at Store

The above integration is also giving rise to lot of new innovating concepts such as Buy Online and pick up at store which utilises the sales channel of internet and the delivery channel of a traditional store delivery. Also lot of retailers are giving increasing visibility into store level inventory which allows customers to buy online and hold the product at a local store for a pick up thereby guaranteeing availability. Retailers are also bringing kiosks into the stores, this way a customer who missed out in a item within the store can purchase it at the store thereby guaranteeing the sale and increasing availability.

3. Direct to Store Delivery

Another concept that is gaining popularity is the direct to store delivery model, which offers vendors to take their items directly to the store and by limiting the number of intermediate delivery centers and warehouses. Unlike the previous two trends, this trend requires physical warehouse capabilities of being able to fulfill requirements directly to store and thereby handle the size of deliveries.

Indeed the true power of internet is only now catching up and revolutioning the retail world.

Procure to Pay for Process Industries

Procure to Pay is a standard business flow in any Organization. In Manufacturing Sector, It is a typical business requirement to pay supplier based on goods finally delivered after inspection. All ERP Systems handles this requirement. This serves Discrete Manufacturer pretty well. But, what about the Process Manufacturer, does it serve well for them too? Let’s see.

 

One of the major challenges, Process manufacturer face, is handling inherent variability in raw material. The raw material which generally sourced from organic sources varies from lot to lot. In Process Industries, it is common to base the price of material on various technical parameters. Since, these parameters known only after the quality department’s testing, it is really hard to decide in advance the price of material that supplier is going to supply in future. So how does Procure to Pay work in Process industries?

 

Following is Procure to Pay business process in typical process industry:

 

  1. Company enters into purchase agreement with supplier. In this agreement, a base price is mutually agreed, which is based on standard values of typical technical parameters applicable to that material.

  2. Supplier supplies the material against this purchase order.

  3. After receipt, Quality Department tests the material, and provides actual value of technical parameters.

  4. Based on standard parameter value in Agreement & actual parameter value, a differential amount is arrived at, after some calculation.

  5. Company applies this differential amount to agreed PO Price and pay the net amount to supplier.

How is it different from Discrete Manufacturing?

  1. It is not just the quantity which affects the Invoice value !

  2. The calculation for differential amount may vary from Industry to Industry, Company to Company & even Supplier to Supplier !!

  3. Generation of Invoice Price Variance (IPV) will become more of routine rather then specific case. In General, IPV point to specific cases and require analysis. Process Manufacturers usually don’t want those IPV which are result of difference in quality from agreed quality in Agreement, as it is considered part of normal business activity.

Typical challenges faced by Implementer in Procure to Pay Cycle for Process Industry are:

  1. Capturing of Technical Parameter Value at the time of Receipt. This requires integration of Receiving module with Quality Module with appropriate real time notifications.

  2. Calculation of Amount to be deducted due to quality differences while paying to supplier

  3. If possible, avoid the IPV generation due to above.

As we can see, Procure-to-Pay Business flow which was fitting so well for Discrete Manufacturer, now looking more complicated for Process Industries. When evaluating any package, we advise process manufacturer to just don’t go by the Vendor Claims or Research Findings, as most of them are done on discrete manufacturing. They would do well by asking vendor about Procure to Pay process mapping in the system beforehand.

 

 

 

 

 

April 15, 2009

IFRS countdown has started, are we ready?

International Financial Reporting Standards (IFRS) will be mandatory in countries like India from April 2011 onwards. As per IFRS guidelines if companies has to report in IFRS based results on 31st March 2012, then transition should start from 1st April 2010 so as to have comparable figure for March 2011.

We are already in April 2009 and still no traction is seen on this topic from listed firms. Also there are various issues specially related to different laws in India that need to be sorted out by ICAI. Few examples like

  • Reporting for Banks as they have prepare financial statements as per Banking Act
  • How to calculate Deperciation in corporate tax books? As per IFRS or companies Act

Seems we are not ready yet.. will it be last minute rush by Indian Firms or we will get extension of deadlines. Let me know your thought..

April 13, 2009

Shared Service Process in Payable- Road Towards continuous Improvements

IT Shared service offer the potential for significant cost savings through economies of scale,process improvements and standardization. Shared services can help companies reduce costs through greater efficiency

In Oracle world, using shared service process coupled with new features of release 12i, organization can now increase their flexibility and responsiveness to market especially by automating processes and streamlining administrative functions apart from reducing overall costs

Lets explore now, what road Oracle has provided to help organizations to move towards continuous improvements and reduce overall cost in current economic meltdown.

 In typical scenario of accounts payables implementation,earlier organizations used to find following roadblocks during implementation of shared service process 

  • Multiple Roles and Responsibilities
  • Less Automation in Accounting Entries
  • No centralized tax engine
  • Integration of Master Data Management
  • Complicated Reporting
  • Less Control

To address all this roadblocks, Oracle has come with various features in Release 12i to help organizations to further enhance its efficiency and effectiveness in shared service process. Some of key features are

  • Multi Org Access Contro (MOAC) features leading to Improvement in Transactions Processing and Control due to less roles and responsibilities
  • Sub Ledger Accounting (SLA) is a Rule based accounting features leading to more accuracy and control. It helps to generate accurate accounting entry based on data input without any customization and users intervention
  • Third Party Architecture helps in integrating various master data management across differemt systems
  • Centralized tax engine providing more automation in defaulting tax code based on various logics and ensuring error-free transaction as no direct users involvement needed.

In shared service world all above features will further translate into process improvements, better control, enhanced effectiveness and efficiency leading to overall cost reductions  

Illustration has been provided below to further eloborate on how new features will increase efficiency and effectiveness of shared service process 

Before 12i, Users has to navigate in different responsibilities to enter invoices meant for different companies/operating unit. For e.g. to enter invoice for Operating Unit A, he has to login into "Payable Manager Operating Unit A" and to enter invoice for operating Unit B, he has to login into "Payables Manager Operating Unit B". Using MOAC, now users at shared service center are no longer required to switch responsibilities. Based on access provided to him, within same responsibilities, he can enter invoices meant for various operating unit thus leading to improvements in transactions processing and better control.

Earlier, before 12i, there were limitations to have multiple liability accounts or to default accounts based on various parameters etc. Hence in shared service scenario, users has to remember what company and what relevant accounts to choose. Now using SLA, this accounting is fully automated. In SLA accounts are derived based on rules engine giving more control and accuracy in process. In SLA based system, user do not have to worry about which Org/Company to choose, what natural account to select. All this is automated by defining derivation rule using different permutation and combinations of data available in system. Now, users have to just key in invoice amount and distributions and everything else is taken care by system.

 

 

April 08, 2009

Architecture dilemma – Do Telcos have the answer?

An optimal BSS/OSS architecture should be able to support customers and products in a way that allows a 360 degree view across multiple channels, be able to support rollout of products and services in quick time, be able to bundle multiple product offerings, be able to instantly provision and activate them and have a single bill for all the products offering for the customer. But in reality most Telcos are quite far from achieving this optimal state
For example a Telco in the middle east region had a custom built all in one CRM and billing system that worked with an Access database based order management system that was neither scalable nor was in line with their ambitious go to market plans for their ADSL line of products. A slightly more matured telco had two stacks each catering to a different product line (mobile and landline) and were struggling to provide a single view of customer since the same customer would sit on each of these stacks if he was to order both landline and mobile from the same operator. Another tier 1 Telco had implemented piece meal point solutions for CRM, billing and product catalog each from a different product vendor and now had invested a lot of money into integrating them together. Each product had its own product support lifecycle and the business had to keep putting in more money to ensure product currency for each product and integrate these new product versions.

So clearly Telcos need to keep their end state architecture in mind based on their business priorities. While tactical decisions to cater to immediate business needs will be unavoidable, each step needs to be carefully chosen based on the end state architecture which will clearly be different for each Telco. Some dilemmas Telcos face today - do we go for an end to end suite from a single product vendor like Oracle, and leverage solutions like the Telco lab, which would offer a quick start and lower TCO due to lower integration and upgrade costs, or do we go for mix of best of breed packages and integrate each of these packages? Do we do a phased approach (remodel the existing legacy stack to reach the end state  which would mean creating tactical interfaces with legacy until cutover) or go big bang (e.g. create a parallel stack and migrate customer into this new stack)? How do we reach our optimal architecture at the lowest cost and shortest time and how far are at present we from achieving this?

Demystifying your Telco structure

The network driven convergence is driving the siloed service driven architecture into a service agnostic customer driven B/OSS architecture. An overhaul of the complete IT landscape is required through a complete process re-engineering. In-addition to the incumbents, new players are entering specific business areas around MNO / MVNO, WiMax depending on country specific regulatory approvals. Once these service providers have network agreements in-place, any delay in launch would significantly impact their ROI in a highly competitive market.
Point solutions based on best of the breed packages based solutions serve its purpose for incremental changes but not for convergence driven changes. The point solutions consume too much organizational bandwidth, increase integration effort, have a high cost of ownership and fall woefully short in deploying convergent organizational processes rapidly. Organizations would need to follow a zero baseline approach for a faster ROI. Infosys can handhold organizations to transform rapidly through Oracle based pre-integrated solution suite based on Telco industry processes. This pre-integrated solution a.k.a Oracle Telco lab solution, offers proactive responses to real life business challenges faced by Communication service providers. The solution is modeled completely on Oracle’s suite of products, the list of technologies and standards that these solutions use to stay best-in-class include eTOM, NGOSS, SID and Oracle’s SOA (supported by AIA framework).

In the wake of increasing competition, decreasing ARPUs, shifting focus to new revenue generating services, communication service providers are more often than not faced with little time to adapt. We can help communication service providers stay ahead of competition by increasing their speed to transform & and agility to launch new services through the industry proven Oracle Telco lab solution. As Jerry Maguire said in the 1996 classic, Jerry Maguire, “help us, help you” .

Process or Discrete manufacturing.. What difference does it make??

 Whenever we talk about process manufacturing, it is assumed similar to Discrete Manufacturing. It also has operations, activities, work orders etc. right? Agree, but it has much more then that. Just an example, how do you measure a computer or Car? By numbers.. 2 computers or 3 Cars.. What about a cup of coffee?? 1 Cup, 200 ml, 190 mg, % Coffee.. In Discrete Manufacturing, 1 plus 1 makes 2, while in Process Manufacturing, It usually less then 2. Complexity of process manufacturing has just started!!!  

Before, we go ahead, let’s see what process manufacturing is:

Process Manufacturing is where the creation of a product is based on a continuous series of processes being applied to raw materials. As per Wikipedia "The simplest and easiest way to grasp the definition of process manufacturing is that, once the output is produced, it can't be distilled back to its basic components. Think about it. Once you make a can of soda, you cannot return it back to its basic components such as carbonated water, citric acid, and other ingredients. You cannot put the juice back into the orange. A car or computer, on the other hand, can be disassembled and the parts, to a large extent, can be returned to stock."

Some of the examples of Process industry include petroleum, chemicals, pharma, food & beverages, textiles, metal, wood, minerals, paper, printing & publishing.

How it differs from Discrete Manufacturing? First & Foremost, the terminology used is different.. Talk about BOM, Components, Job Orders, Assembly, Fabrications to process manufacturer, and he will give you strange look. It is like talking Chinese to an American Frown  Talk about Formulations, Recipe, Mixing, Blending, Transforming, and you have created a great first impression Smile

Another difference is inherent variability in Raw Material. Most of the Raw Material is sourced from Organic sources & hence the variability. In fact, the overall objective of process manufacturing is to keep the variability within acceptable range in final product. What is acceptable range? This question leads to another downstream question, how do we measure the variability? There are lots of technical parameters used to measure the variability, few of them are Generic like Density, Temperature & few are Industry Specific Parameter, for ex: %SNF for Milk. You can see the importance of Quality in process manufacturing.

Raw Material in process industry varies with time also. In most of the cases, Expiry Date come attached with Lots. In few Perishable products, like milk, Curd etc, Shelf life is short and hence Supply chain planning for such products is critical to achieve maximum benefit & minimum waste.

BOM & Formula are not just the difference of terminology. While in BOM, there is only one output, in Formula, there can be more then one products. To add to complexity, these products may not be produced in final stage, but can be in intermediate stages too. Another point to note about formula is that, it not only contains Ingredients, but also their technical parameter. Most of the Process industries rely on Computer added formulations to derive the approximate quantity & quality of product produced. 

Another complication is Compliance & Traceability. Take example of Pharmaceutical industry, where 21 CFR Part 11 is applicable or F&B Industry where regulations like Bio terrorism Act, HACCP are applicable. Chemical Industry which handles hazardous material has to adhere to numerous Safety Regulations. Remember the Bhopal Union Carbide Case, and importance of such compliance will immediately clear. Lot traceability is another area to look into to ensure minimum damage if a Bad Lot is somehow used in few batches. A bad lot can risk not only the Image of company, but may result in Criminal proceedings.

So, what should we take out from above analysis? Process Industry's challenges are far greater then Discrete Manufacturer. It not only has to face generic challenges like Globalization,  Competition, Reduced Time to Market but also process specific challenges like Stricter Compliance, Variability, Process complexity.  How Process industries are using ERP to address some of these challenges will be subject matter of my future blogs.

April 01, 2009

Failure of Peanut Corp. of America, what should we learn??

On 13 Jan 09, Peanut Corporation of America (PCA), announced a nationwide voluntary recall of peanut butter suspected to be contaminated with Salmonella. The call was extended further to include more products & lots. On 13 Feb 09, PCA filed for bankruptcy under chapter 7.

The peanut butter and peanut paste recall have been considered the largest product recall in history. Nine people have been died & thousands have reported sick due to consumption of PCA products. Questions are being raised about the food safety regulations & quality issue in Supply chain. Is it the system Failure or Greed of few individuals? Is it only the PCA whom to blame? What about the downstream Manufacturer who were using PCA products as their Raw Material? Also, are our Quality regulations sufficient? But the most important question that most Food companies should be asking themselves is this, what to do to avoid the repetition of same in future? 

While FDA will do their job to strengthen the Regulations, for food companies, implementation of a good ERP system can be a good start. A best-in-class ERP system provide sufficient checks to ensure quality across supply chain. It also provides traceability to identify and minimize the damage.

HACCP is framework for food safety which ensures identification & analysis of Critical control point in supply chain. Process ERP, like Oracle Process Manufacturing (OPM) suite of application from Oracle, are designed keeping in mind specific requirement for Food Industry.  ERP help in HACCP certification by providing various Quality management tools for controlling & monitoring of production operations. For example, it is possible to stop further processing until current step is approved by Quality department. In addition, ERP provides full audit trail & standard security feature.

In case of Product Recall, time plays critical role. With Product Recall, it is Company’s reputation that is at stake. The information of contaminated batches must reach to regulation authorities & public as soon as possible. Delay can not only result in severe criminal proceedings, it may end in company going out of business. 

Bi-directional Lot traceability is required in Recall. Once Contaminated lot of product reported, either through Customer complaint or through Authority Inspection, the first step to identify the point of contamination. Then, point of contamination can be used as source to find all contaminated batches. Once identified, the next step to identify the customer to whom the lot is shipped. The information should flow to all the affected customers, so that they can identify their contaminated lots of products. Take an example, a manufacturer use contaminated lot in 100 Batches (10 products with 10 batches each). For simplicity we can assume these batches shipped to 20 customers who use it in their 10 batches producing 500 packs each. While total number of contaminated batches would be 200, the actual no of packs will be 100,000. Also, there will be unused contaminated stock lying at manufacturer & its customer site. This is simplified case, in real scenario, these numbers can be huge. Think about the time it will take for company relying on Customized (Generic or Discrete ERP usually force fit to process industries) & Outdated IT systems to identify the all contaminated batches. Also, with data in separate Systems, what’s the guarantee of accuracy? If it’s a Class I recall, just one missed batch may be sufficient to put company’s CEO behind the bar.

With Process ERP, like OPM, where data is available centrally, it’s just matter of few hours to find all contaminated batches & take quick action before situation go out of hand.  

With alarming rise in Food Safety Cases & Product Recall, It is high time to look for investment in solid Process ERP which is designed to meet to Industry specific requirement and give you peace of mind!!

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