Cosmolab Inc., the largest private label manufacturer of color cosmetics in the U.S., and a MAC-PAC user since 1989, recently implemented the MAC-PAC XE Business Process Manager (BPM) module as part of a project to further tighten control of inventory. BPM provides a framework for automatically generating 'alerts' when certain events or conditions are detected within the MAC-PAC XE database. Queries are used to monitor for conditions and generated alerts are directed to appropriate people for display on their MAC-PAC XE screens.
As a contract manufacturer, Cosmolab is continually introducing and retiring different part numbers based on minor changes such as packaging. That makes effective management of issues like BOM releases, component part use-up, customer-specific purchase order monitoring, etc. critical to being able to optimize inventory.
After attending the TDCI's "Perspectives 2005", Cosmolab made the decision to implement Business Process Manager as an enhancement to existing systems. Julie Johnsey, Inventory Project Manager, took the lead on the implementation. Julie's team identified 13 'events' - conditions that could cause unnecessary inventory build, lost usage opportunities, or delayed production start-up. The events were related to certain types of SO, PO, and MO changes; new, missing, and changed BOMs; significant cycle count changes; and other situations that could affect inventory or required manual research. Those events became the focal point for an on-site TDCI training class on BPM where approaches were defined and many of the events were actually developed and tested.
The results were almost immediate. For example a BPM event was defined that completely eliminates the need for Cosmolab's BOM Engineer to manually track purchased component phase-outs. It automatically detects, well in advance, when the old part will be consumed and notifies the Engineer the effective date of the new part. Another was defined to automatically notify project coordinators what BOMs need to be released to support production of new products. Commenting shortly after the training session, Julie said: "BPM is an excellent work flow and priority setting tool. .early indicators are that that we will meet or exceed our expectations for generating the efficiencies and savings we projected."
Julie and the Cosmolab team were pleasantly surprised at how easy BPM is to set up and use. According to Julie: "This program is so easy for the user, it's almost self explanatory." Every training session has generated more requests to complement existing systems.
Summarizing her team's feeling about BPM after just a short time using it: "I would recommend BPM to any company that uses MAC-PAC and has specific information that needs to be monitored. It's already providing information instantly that previously took a great deal of time to research."
To learn more about BPM, discuss how it might help your company achieve operational improvement objectives, or schedule an on-site class, contact Shelley Horn at shorn@tdci.com or 614-781-2325 x119.
