My Supply Planning Stint

By Chika Obuah

18th April 2012

The U2K2 ProjectThis is about using the SAP Supply Chain Management (SCM) software to help improve and optimize the Central Africa (CA) supply chain by enabling automated decision making, providing improved analytical tools to users, and sharing information with internal system users and external business partners in a timely and efficient way.

Line Manager: Stephen Makau CPL Planning U2K2 CA

Business wasteThe LT approved the disposal of raw materials, packaging materials and finished goods. The project is about the efficient disposal and recovery –if possible.

Line Manager: Bode Omosagba Supply Planning and Inbound logistics manager, Nigeria.

My Projects

Objectives

Design an SAP SCM solution that will help transform our supply chain into a responsive supply network – in which the business can share knowledge and intelligently adapt to changing market conditions.

Work with the Regional Access Control team (RAC) and Accenture team to build it.

Test the solution to ensure the solution is designed to specification and meets the business needs.

Train the end users on how to use the solution.

Seamlessly cutover over from the legacy system to the SAP U2k2 solution.

Duration

January 2011 to April 30th 2012

The U2K2 Project

Developed the detailed design document for production planning and detailed scheduling (PPDS) for Central Africa

I Led the CA team (Nigeria, Ghana, CDI, Kenya, Zimbabwe, Malawi and Mozambique), the RAC team based in Turkey, the Process office based in Singapore on meetings and workshops on PPDS (U2K2 WS2 and WS3) in Kenya, Ghana and remotely which eventually led to the design of the detailed PPDS document for Central Africa- the design document that shows how production will be run in CA.

Improved design process

During the design phase, I developed an excel based tool (I call the Production Matrix) to show the priority of SKU’s across packing lines. This helped the team easily determine the resources to group together, reduced the time required to fill resource priority based templates and gave clarity at a glance as to how products were produced across CA.

Also, with the help of planners and production managers across CA, I developed a PowerPoint presentation that showed in graphical terms the constraints in the various factories across CA. It helped us track and document recommended planning solutions such as secondary resource definitions and grouping of resources. I visited all the factories in Kenya, Zimbabwe, Ghana and Nigeria.

Design Phase

LearningsI have learnt to work cooperatively with others to achieve shared goals, to show diplomacy and flexibility when there are conflicting opinions.

Design Document

CA Factories PPT

Production Matrix

Developed the masterdata required to enter the build phase

With the help of planners in Nigeria, I developed the product master data, production resource masterdata, break, shift, shift sequence, capacity variant, PDS masterdata, setup group, setup key and setup matrix templates. All of which are masterdata information require to build the solution.

Design Phase cont’d

LearningsI learnt SAP APO.

During this phase of the project, I was on standby to give clarity to the core development team (the RAC) on our business process when required. I also participated in trainings that equipped me with the required knowledge to test the solution.

Build Phase

Led WA Team in ITC1

The testing phase was divided into 3 parts; Integrated test cycle 1 (ITC1-which had a scope of cluster and I was in the West African cluster), Integrated test cycle 2 (ITC2-which had a scope of country and I was in the Nigerian team), and User acceptance testing (UAT-also had the scope of country).

In ITC1, I led the West African (WA) planning team comprising of planners from Nigeria, CDI and Ghana in the testing of the solution developed. The aim of ITC1 was to test the functionalities of the solution built. I ensured the testing schedule was adhered to and optimized our speed through division of labour and simultaneously testing similar processes with the entire team-like material requirement planning drilldowns. I also ensured all issues encountered were recorded as Test Problem Reports and picked up with appropriate quarters for WA.

At the end of ITC1 I was given the Leo Award in recognition of the quality and speed of execution.

Testing Phase

LearningsI have developed my ability to act as a catalyst in developing a group of individuals into an effective team. I am better at Inspiring and energising others to carry out tasks and achieve goals, by displaying a clear sense of direction and values.

LEO LEO Announcement

Led the Nigerian planning team in ITC2 and UAT

In ITC2 and UAT, I led the Nigerian planning team, performing the same functions as I did in ITC1. In ITC1 we tested the functionalities with small volume of data, in ITC2 put the system through over 90% of actual company volume.

The UAT was the last phase of testing. I led the team in testing end to end scenarios, to verify the system result by final solution users (UAT test users), based on the agreed design, so as to ensure that the system design met business requirements.

Testing Phase cont’d

LearningsLeading a team that consitently led has fired up my passion for growth and winning. I am now positively biased towards taking the lead , seeking fresh opportunities and never settling for 'good enough'.

I have successfully trained the key users in; SAP business overview, Supply Network Planning and Production planning and detailed scheduling and will take them on Distribution Requirement Planning next month. These skills are required for the roles of Supply/ Production Planning and export planning.

Training

LearningsMy customer is anyone who receives a service from me.I had the opportunity to Influence conservative opinions on old ways of working by expressing my viewpoint with conviction and by using appropriate interpersonal styles and communication methods to gain acceptance and build commitment to the new solution.

In this phase of the project, I have participated in two simulations; Full Dress Rehearsal 1 and Full Dress Rehearsal 2- the movement of data from the legacy system to the new system. I also led the team on the Product Validation Test and then participate in the actual cutover.

Cutover

Objectives

Confirm the physical availability of the stock.

Classify appropriately the items involved into, discrepancy, what is sellable, good for “give away” to employees or to be destroyed.

Co-ordinate the sales of the scrap.

Work with SHEQ and Treasury (Finance) team for the on-time destruction of items to be destroyed.

Give recommendation on the modality for stock good for “give away” to employees.

Duration

June to September 2011November 2011 till March 2012

Business Waste Project

Worked remotely with the team 90% of the timeSince we (the team members) still had other jobs we did, I promoted agile working and this greatly reduced the number of meetings we had. Throughout the project so far, we have only had 3 physical meetings!

Developed my Standard Operating Procedure for material disposalI learnt the process, the pros and the cons on the job. So, I developed my own SOP I believe will help anyone who takes up the task later.

Successful multitaskingI successfully managed the complex combination of the two big opportunities- the opportunity to lead a team of planners in WA on the U2K2 project and to lead a committee setup to efficiently dispose business waste.

What I did differently

LearningsI have learnt first hand how small actions can make a big dent on the bottom line. I have also learnt how to think holistically to salvage mistakes and to see opportunities everywhere.

chika.obuah@unilever.com