U.S. patent application number 11/176585 was filed with the patent office on 2005-12-01 for method and system for monitoring a supply-chain.
This patent application is currently assigned to elcommerce.com.inc.. Invention is credited to Perry, Brain M..
Application Number | 20050265083 11/176585 |
Document ID | / |
Family ID | 34992078 |
Filed Date | 2005-12-01 |
United States Patent
Application |
20050265083 |
Kind Code |
A1 |
Perry, Brain M. |
December 1, 2005 |
Method and system for monitoring a supply-chain
Abstract
A method of monitoring supply chain activity throughout a
plurality of supply chain sites includes extracting, at each supply
chain site, supply-related data to be monitored. The data is
maintained in plural formats at the supply chain sites, and
translated the data to a common format. The extracted data is then
uploaded to and collected, from each supply chain site, to a data
collection center or site. Upon a user request, a portion of the
collected data is formatted, at the data collection site, into one
of a plurality of views, responsive to criteria selected by the
user, for presentation to the user, the portion of formatted data
being dependent on access rights granted to the user's supply chain
site. Finally, the formatted data view is published to the user's
supply chain site. The data collection center comprises a data
collector in which the uploaded data is stored, and a publisher for
publishing data from the data collector upon request. Each supply
chain site has a data storage device for maintaining its own
supply-chain data, a data transfer engine (DTE), for transferring
the supply-chain data to the data collection center, input means
for allowing a user to query the data collector, and a display for
displaying data published by the publisher in response to a query.
The inbound data received from the multiple supply chain sites is
monitored at the data collection site. If a problem condition is
detected, such as a forecasted or present shortage or surplus, an
alert is asserted, for example, by highlighting an Alert indicator,
such as an Alert tab, on a user screen. Upon selection of the
highlighted Alert indicator by a user, details of the detected
problem condition are displayed.
Inventors: |
Perry, Brain M.; (Upton,
MA) |
Correspondence
Address: |
HAMILTON, BROOK, SMITH & REYNOLDS, P.C.
530 VIRGINIA ROAD
P.O. BOX 9133
CONCORD
MA
01742-9133
US
|
Assignee: |
elcommerce.com.inc.
Holliston
MA
|
Family ID: |
34992078 |
Appl. No.: |
11/176585 |
Filed: |
July 7, 2005 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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11176585 |
Jul 7, 2005 |
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09546347 |
Apr 7, 2000 |
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6947903 |
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60147670 |
Aug 6, 1999 |
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Current U.S.
Class: |
365/189.07 ;
365/200; 365/201 |
Current CPC
Class: |
G06Q 10/087 20130101;
G06Q 10/06 20130101 |
Class at
Publication: |
365/189.01 |
International
Class: |
G11C 005/00 |
Claims
What is claimed is:
1. A data importation method comprising: receiving first product
data in a first format; comparing the first product data with
second product data previously received; reviewing results of the
comparison to determine whether there is a problem with the first
product data; changing a format of the first product data to a
standard format; comparing the standard format first product data
with third product data, the third product data corresponding to
the second product data having format changed to the standard
format; placing the standard format first product data in a
category based on the comparison of the standard format first
product data with the third product data; and generating statistics
based on the comparison of the standard format first product data
with the third product data.
2. The method of claim 1, wherein placing the standard format first
product data in a category comprises placing the standard format
first product data in an identical products file.
3. The method of claim 1, wherein placing the standard format first
product data in a category comprises placing the standard format
first product data in a new products file.
4. The method of claim 3, further comprising: retrieving original
supplier data for an original supplier product; normalizing at
least one company in the retrieved supplier data; looking up the
original supplier product in a product database to determine
whether data corresponding to the original supplier product has
been provided by other suppliers; locating a template for the
original supplier product corresponding to the retrieved supplier
data; normalizing at least one attribute from the retrieved
supplier data by using the template; defining normalized product
data as the supplier data having the normalized at least one
company and the normalized at least one attribute; and inserting
the normalized product data into the product database.
5. The method of claim 4, wherein the step of normalizing at least
one company comprises normalizing vendors and manufacturers
associated with the product.
6. The method of claim 4, wherein the looking the product up step
comprises determining whether the retrieved product data already
exists in the product database.
7. The method of claim 6, further comprising: comparing the
normalized at least one attribute with existing attributes;
selecting correct attribute values; and updating the normalized
product data in the product database with the correct attribute
values.
8. The method of claim 4, further comprising a step of updating
attribution definitions before the step of inserting the normalized
product data.
9. The method of claim 4, further comprising: identifying a
category associated with the original supplier product; retrieving
original supplier data for other original supplier products; and
optionally assigning to the located template all products in the
other supplier original products corresponding to the identified
category.
10. The method of claim 1, wherein placing the standard format
first product data in a category comprises placing the standard
format first product data in a changed products file.
11. The method of claim 1, wherein placing the standard format
first product data in a category comprises placing the standard
format first product data in a deleted products file.
12. The method of claim 11, further comprising: retrieving product
data from the delete products file; looking up the retrieved
product data in the product database; deleting from the database
the retrieved product data, which corresponds to a first supplier,
when a product corresponding to the retrieved product data has not
been deleted for all other suppliers.
13. The method of claim 1, wherein placing the standard format
first product data in a category comprises placing the standard
format first product data in a faulty products file.
Description
RELATED APPLICATION
[0001] This Application is a continuation of U.S. application Ser.
No. 09/546,347, filed Apr. 7, 2000, which claims the benefit of
U.S. Provisional Application No. 60/147,670 filed on Aug. 6, 1999,
and is related to application Ser. No. 09/544,916, filed Apr. 7,
2000; the entire teachings of which are incorporated herein by
reference in their entirety.
BACKGROUND OF THE INVENTION
[0002] A typical manufacturing supply chain includes an original
equipment manufacturer ("OEM"), which designs and sells equipment
such as computers or other electronic equipment. To keep costs
down, OEMs often contract out the manufacture of at least some of
the individual components of the product, such as electronic
boards, to contract manufacturers ("CMs"). The CMs must obtain the
parts with which to build the boards, such as resistors and
integrated circuits, which are manufactured by component
manufacturers or vendors. The components are typically not sold
directly to the CMs but rather are sold through distributors.
[0003] For example, FIG. 1A illustrates a supply chain 2 as is well
known in the art. Included in the supply chain 2 are a distributer
16, an original equipment manufacturer (OEM) 12, one or more
contract manufactures 14, and one or more vendors 18. As indicated
in the figure, each of these sites must communicate with one or
more of the other sites as indicated by the arrows.
[0004] Each node or link in the supply chain, i.e., each OEMs,
distributor, CM and vendor, typically maintains its own private
database to track and control inventory, place orders, receive
orders, enterprise resource planning (ERP), material requirements
planning (MRP), etc. While these supply chain sites share some
data, the data is typically maintained in incompatible formats in
legacy databases.
[0005] The Electronic Data Interchange ("EDI") standards have been
developed to aid in the interchange of information to expedite
business transactions by specifying a consistent data interchange
format. Yet, in practice, how each supply chain site deals with its
external environment, i.e., vendors, CMs, customers, has often been
archaic and inconsistent.
[0006] Supply chain management is difficult because it depends on
the axiom that a business has fundamentally correct processes.
Unless the foundation for activity is well thought out, managing
the chain further aggravates a company's environment. For example,
not all of the information needed may be available on the legacy
databases. Often, teams of programmers are utilized to implement
custom design changes to these legacy databases that become
overwhelmingly complex. Whether these changes are implemented by
outside consultants or by in-house staff, lack of clear project
goals, effective monitoring and performance review constantly
plague the process.
SUMMARY OF THE INVENTION
[0007] The present invention eliminates much of the confusion which
results from redesigning one or more complex legacy systems.
Instead, legacy systems are left intact, and a data transfer engine
("DTE") is installed at each site. The DTE monitors the local
system continuously, and takes whatever information is available.
While a complete picture of the supply chain may not be provided if
not all information is available, for example, if a certain
attribute is not tracked at a particular site, the DTE takes
whatever data is available, cleans up the data, and formats the
data into a common format acceptable to a data collection site. The
DTE then transmits or uploads the data to the data collection site,
which is preferably a distributor or an OEM.
[0008] While some custom programming is required to extract the
proper information and clean it up, no change to the existing
business process is required. The programming that is required for
extracting and cleaning the data is minimal compared to the major
rewriting or restructuring necessary for previous known
methods.
[0009] The ability to collect data and lay it out before a user in
logically configured views where sources and demands are made
visible, and where every view is within two or three mouse clicks
away, gives unprecedented power to OEMs and distributors to
monitor, analyze and control the supply chain. The present
invention provides information management and analysis capabilities
at the component level for manufacturers, vendors and distributors
operating in partnership to manufacture subassemblies that combine
to produce a finished OEM product.
[0010] The present invention facilitates the relationships between
the OEM, distributor, CMs and vendors (collectively, the "sites")
in the context of raw materials flow through the supply chain. A
great benefit of the present invention lies in its ability to
aggregate or collect, analyze, and inform multiple parties about
the status of materials that move through their shared supply
chain, directly influencing the success of each.
[0011] Accordingly, a method of monitoring supply chain activity
throughout a plurality of supply chain sites, includes extracting,
at each supply chain site, supply-related data to be monitored. The
data is maintained in plural formats at the supply chain sites. The
extracted data is then uploaded to and collected, from each supply
chain site, to a data collection center or site, where it is stored
in a common format. Upon a user request, a portion of the collected
data is formatted, at the data collection site, into one of a
plurality of views, responsive to criteria selected by the user,
for presentation to the user, the portion of formatted data being
dependent on access rights granted to the user's supply chain site.
Finally, the formatted data view is published to the user's supply
chain site.
[0012] The data collection center comprises a data collector in
which the uploaded data is stored, and a publisher for publishing
data from the data collector upon request. Each supply chain site
has a data storage device for maintaining its own supply-chain
data, a data transfer engine (DTE), for transferring the
supply-chain data to the data collection center, input means for
allowing a user to query the data collector, and a display for
displaying data published by the publisher in response to a
query.
[0013] In one embodiment, the data is translated at each supply
chain site before uploading. Alternatively, the data is translated
at the data collection site after uploading.
[0014] In one embodiment, each supply chain site is scanned at
regular intervals for new or changed data. Upon finding new or
changed data, the new or changed data are uploaded to the data
collection site.
[0015] Plural formats can include, but are not limited to,
spreadsheets, relational databases and text files. One skilled in
the art would recognize that spreadsheets and databases themselves
vary from vendor to vendor, and even two implementations using the
same vendor's spreadsheet or database or text file will have data
configured and/or formatted differently.
[0016] Data can include, but is not limited to, inventory data,
purchase orders and lead time.
[0017] Data at the supply chain sites can be stored in legacy
databases, that is, databases, spreadsheets, text files, and the
like, which exist before implementation of the present
invention.
[0018] In a further embodiment, the inbound data received from the
multiple supply chain sites is monitored at the data collection
site. If a problem condition is detected, such as a forecasted or
present shortage or surplus, an alert is asserted, for example, by
highlighting an alert indicator, such as an alert tab, on a user
screen. Other possible alert condition indicators are, for example,
a highlighted box or button, or a line of data in one of the
screens corresponding to, say, a part number which is in an alert
condition.
[0019] Upon selection of the highlighted alert indicator by a user,
details of the detected problem condition are displayed. In one
embodiment, the alert details are displayed in a bar graph. In
another embodiment, alert details are displayed in a line
graph.
[0020] In one aspect of the invention, animation is used to present
data to a user. Specifically, data sets are shown within a
historical basis and changes are shown evolving in animated real
time.
[0021] Supply chain sites can include any or all of contract
managers (CMs), vendors, distributors and an original equipment
manufacturer (OEM).
[0022] In one embodiment, the data is encrypted before
uploading.
[0023] Preferably, uploading the data is performed over the
Internet.
[0024] In a further embodiment, materials requirements information
are provided for a product at any or all stages in the product's
lifecycle.
[0025] An analysis report is generated responsive to report
selection by a user. The generated report is provided, responsive
to user selection of report destinations, by emailing, printing,
storing as a file or displaying on a monitor or a screen, the
report.
[0026] Data is displayed in a window at a site's display according
to a category selected by a user at the site, in response to
authorization granted, for example, to the site, or to the
user.
[0027] For each category, at least one analysis filter is
selectable by the user for setting criteria to be used in filtering
the data to be displayed. Filtering can include, for example,
sorting and/or excluding certain data. Filters are preferably
organized hierarchically.
BRIEF DESCRIPTION OF THE DRAWINGS
[0028] The foregoing and other objects, features and advantages of
the invention will be apparent from the following more particular
description of preferred embodiments of the invention, as
illustrated in the accompanying drawings in which like reference
characters refer to the same parts throughout the different views.
The drawings are not necessarily to scale, emphasis instead being
placed upon illustrating the principles of the invention.
[0029] FIG. 1A is a block diagram illustrating a typical supply
chain as known in the prior art.
[0030] FIG. 1B is a block diagram illustrating a typical supply
chain in which the present invention is employed.
[0031] FIG. 1C is a schematic diagram illustrating that part of the
present invention to be employed at each participating supply chain
site.
[0032] FIG. 1D is a schematic diagram illustrating that part of the
present invention to be employed at the data collection site.
[0033] FIG. 1E is a flowchart of the process employed by an
embodiment of the present invention.
[0034] FIG. 2 is a screen shot of a login window employed by the
present invention.
[0035] FIG. 3A is a screen shot of board data for all active
boards, sorted by board number.
[0036] FIG. 3B is a screen shot similar to that shown in FIG. 3A,
showing the associated pull-down menu.
[0037] FIG. 3C is a screen shot of board data resulting from the
selection made from the pull-down menu shown in FIG. 3B.
[0038] FIG. 4 is a screen shot of board data for boards using parts
sold by a particular distributor.
[0039] FIG. 5A is a screen shot of parts demand information for a
particular distributor.
[0040] FIG. 5B is a screen shot similar to that of FIG. 5A, showing
the associated pull-down menu.
[0041] FIG. 5C is a screen shot of parts information showing demand
through lead time for a particular part, resulting from the
selection made from the pull-down menu shown in FIG. 5B.
[0042] FIG. 6 is a screen shot of MRP data by board.
[0043] FIG. 7A is a screen shot of vendor data.
[0044] FIG. 7B is a screen shot similar to that of FIG. 7A, showing
the associated pull-down menu.
[0045] FIG. 8 is a screen shot of sales data.
[0046] FIG. 9 is a screen shot of the reports ordering window.
[0047] FIG. 10 is a screen shot of a typical report sent to the
screen.
[0048] FIGS. 11A-11C are screen shots of the alert window of the
present invention.
[0049] FIG. 11D is a screen shot of an alternate alert window for
use with the present invention.
[0050] FIG. 12 is a graph illustrating the use of animation by the
present invention to present data.
DETAILED DESCRIPTION OF THE INVENTION
[0051] FIG. 1B illustrates a supply chain 10 environment in which
the present invention is employed. An original equipment
manufacturer ("OEM") 12 designs products, assembles the products or
contracts assembly out, receives sales orders ("SOs") from
customers and generates purchase orders ("POs") to obtain the parts
required to build the ordered equipment.
[0052] The POs may be sent to contract manufacturers ("CMs") 14,
who build, for example, boards which typically have 50 to 200 or
more parts. The OEM 12 may contract with several CMs 14 to build
the same board, and/or may contract with different CMs for
different boards. Here, for example, several contract manufacturers
CM-A through CM-D are depicted.
[0053] The CMs 14 themselves must obtain the required parts or
components, such as resistors, capacitors, semi-conductors, knobs,
indicators, hinges, switches, buttons, etc., either directly from
the component manufacturers, or vendors 18, or more typically, from
one or more distributors 16, who generally keep inventories in
stock which they (the distributors) believe will satisfy
foreseeable demand.
[0054] In addition, depending on how much of the manufacturing
process the OEM 12 retains for itself, the OEM may also obtain
parts directly from vendors 18 or through distributors 16.
[0055] Different components and boards have different lead times,
which may be dependent on the availability or lead times of
components, in the case of boards, or other factors, such as a
particular vendor's or CM's build schedule. That is, different
items take longer than others to order, design, produce, ship
etc.
[0056] Each of the organizations or sites 12-18 in the supply chain
10 is concerned with what to build and, given lead times and
existing inventory, when to build and ship, so that the equipment
ordered from the OEM 12 can be built and delivered in a timely
fashion.
[0057] The present invention makes information regarding current
orders, lead times, parts, etc. available to some or all of the
supply chain sites, by collecting the data at a central site 16A
and selectively publishing that data to the other sites upon
request. In the embodiment of FIG. 1B, the central site 16A is
located at the distributor 16. In practice, the actual location
could be anywhere. In one embodiment, it is controlled by the OEM
12.
[0058] FIG. 1C is a schematic diagram illustrating that part of the
present invention to be employed at each participating supply chain
site. Box 19 represents any of the sites 12-18 of FIG. 1B. Each
organization or site 19 typically maintains its own data storage
devices containing legacy information such as enterprise resource
planning (ERP) data, material resource planning (MRP) data,
purchasing information, inventory, etc.
[0059] This information may be maintained, for example in text
files such as ASCII files 24, spreadsheets 22, and/or databases 20.
The formats of such data may be proprietary or customized. One site
might use one type of spreadsheet while another site uses another
kind of spreadsheet. Similarly, one site might use a particular
database while another site uses a different database. Even
databases bought from the same database provider may be customized
so that similar data is maintained differently at different sites.
Furthermore, some sites may not retain certain data, having deemed
it unimportant.
[0060] Before the development of the present invention, with all of
these different legacy systems in place at the various supply chain
sites 19, OEM verification of data, such as purchase orders and
inventory, was extremely difficult. The quality of data from the
various sites 19 is clouded because there is no lowest common
denominator.
[0061] In the past, teams of Information Technology software
engineers have typically re-engineered the existing systems. This
can be a huge data conversion and software integration effort, even
at a single site, and becomes much more problematic when trying to
make the data uniform across independent contract manufacturers and
vendors who likely will not be eager to redesign their business
method and database. Even the Electronic Data Interchange ("EDI")
specification does not provide enough structure to ensure that
users use it properly.
[0062] On the other hand, the present invention takes data as it
exists on each site's legacy system. Data from all of the sites is
collected at the center hub 16A, or data collection site, which is
preferably the distributor 16 or the OEM 12, and selectively
published to the sites 19.
[0063] Data is retrieved from each site 19 by installing at each
site a data transfer engine (DTE) 26, preferably implemented in
software. The DTE takes data in any size or format, including
various databases 24 and/or spreadsheets 22 and/or text files such
as ASCII files 20, and corrects, translates and formats the data
into "clean" data. In one embodiment, the DTE looks for changes to
data and uploads new data to the data collection site 16A upon
finding a change. Alternatively, the DTE may upload data upon some
other trigger such as the end of a time period, or may upload data
in response to a request from the data collection site 16A.
[0064] Communication between a site 19 and the data collection site
16A can be by any well-known means 40, for example, over the
Internet or via a dial-up connection, or via a virtual private
network (VPN). In one embodiment, the data is formatted using a
formatting language such as XML. In one embodiment, all data
transfers are encrypted. Web servers and browsers can also be
employed.
[0065] The present invention is thus passive in that it takes
whatever data a site has, for example, extracting data from any
popular database, such as Oracle, SAP, Sybase, Bahn, etc., or from
spreadsheets such as Lotus, or any data reduced to an ASCII or EDI
file, or any other formatted file. No redesign or re-engineering is
required.
[0066] FIG. 1D is a schematic diagram illustrating the components
of the present invention employed at the data collection site 16A.
A data collection database 34 or an equivalent data storage system
collects the data sent by each DTE 26 (FIG. 1C). A publisher 36
receives query requests from the various sites 19, and depending on
the access rights granted to a particular requesting site, formats
and publishes the relevant supply-chain data to the requesting
site, which then displays the data in a logical format as described
below on a monitor 28 (FIG. 1C).
[0067] Each site 19 which accesses the collected data requires one
or more computers, each of which typically comprises a monitor 28
for showing the requested information or report, a keyboard 30 for
entering certain information, and a mouse 32 for navigating through
the screens.
[0068] FIG. 1E is a flow chart 70 illustrating the general process
of an embodiment of the present invention. A typical supply chain
site 19 is shown on the left side of the figure while the data
collection site 16A is shown on the right side of the figure. Where
possible, reference numbers correspond to those used in FIGS. 1C
and 1D.
[0069] The data transfer engine 26 extracts data in step 72 from
various formatted data, for example a database 20, an ASCII text
file 24, or a spreadsheet 22. After the data is extracted, it is
translated to a common format in step 74 in one embodiment. After
translation in step 74, the data is uploaded in step 76 to the data
collection site 16A were it is received in step 78. Alternatively,
translation could be done after upload. The received data is then
collected and stored in, for example, a database 34 (step 80).
[0070] This process of data extraction uploading and collection of
the data at the data collection site 16A can be preformed
regularly, upon the expiration of the predetermined time period or,
for example, when a change in the data is detected at the supply
chain site 19.
[0071] At some later time, a user requests certain data at step 82,
at the supply chain site 19. This request is forwarded to the data
collection site. In response, the data collection site 16A formats
the data (step 84) and publishes the formatted data (step 86) to
the supply chain site 19. The published data is then view or stored
or printed, as in step 88.
[0072] FIG. 2 shows a login or "splash" window 50 as might appear
on a site's computer monitor 28 upon a user logging into the data
collection site 16A. The login window 50 builds on the theme of
collaboration between the contract manufacturers that produce the
foundation of an OEM's products. Preferably, images containing
company names and/or logos or trademarks are displayed for the OEM
at 51, and for the contract manufacturers at 53. In one embodiment,
these images 51, 53 are links to connect directly to the specific
company. In the sample screen, the distributor, whose logo 52 is
displayed at the top, is the data collection site.
[0073] Text entry blocks 55, 57 are provided for entering a user
identification (ID) and password respectively. After entering
these, a user clicks on "OK" 59 to have his ID and password
verified, or clicks on "Exit" 61 to exit.
[0074] In the example embodiment, once a user has properly logged
in, all data pertains to the specific OEM. In other embodiments, a
distributor might select from among a plurality of OEMs, for
example, via a pull-down menu. In yet another embodiment, an OEM
dealing with multiple distributors could select from among a
plurality of distributors.
[0075] FIG. 3A is a screen shot 100 of circuit board data for all
active boards, sorted by board number. In one embodiment, this view
100 is the default screen shown to a user after a successful
login.
[0076] Common to all screens after logging in is the set of tabs
102 which allow the user to navigate quickly to the desired
information. When the "Boards" tab 102A is selected, a list of
filters 104A specific to the display of board-related information
is displayed. In the view 100 shown, the filter list 104A is
divided logically into two groups.
[0077] The first group of filters, labeled "Board Type", comprises
six filters in the embodiment shown. By selecting a particular
filter, the user can choose to see only boards of a particular
status, for example, boards that are classified as one of Active,
Pre-production, Engineering or Obsolete. In addition, in this
particular embodiment, Active boards can be sorted either by board
number ("Active by Board") or by contract manufacturer ("Active by
CM"). Finally, selecting "Combined" shows all boards. It will be
obvious to one skilled in the art that other criteria for selecting
and sorting boards can be provided. Thus, materials requirements
information may be viewed for products at all stages in their
lifecycle.
[0078] In the screen 100 of FIG. 3A, the "Board Type--Active by
Board" filter has been selected. That is, the user has requested
information on all boards having a status of "Active". All "Active"
boards are listed in order according to the OEM's board number.
[0079] The requested information for each "active" board is
retrieved from the data collection site's database 34 (FIG. 1C),
sent by the publisher 36 to the requesting site, and displayed on
the requesting site's monitor 28 in various columns or fields. This
data may include, for example, the board's OEM part number 106,
name 108, manufacturer 110, status 112, and projected delivery date
114, 116 for the corresponding manufacturer.
[0080] Because the user has selected the "Active by Board" filter,
boards are listed alphanumerically by board part number 106. Note
that each entry in the board column has an arrow 107 for viewing a
pull-down menu, described below with respect to FIG. 3B.
[0081] In the "Board Name" field 108, a board name is provided if
it is known to the system. The "Manufacturer" field 110 shows the
name of a CM that manufactures the board. Note that each
manufacturer can assign the same board a different name, or not
assign any name at all.
[0082] The "Status" field 112 shows the status of each board. Of
course, available statuses can be different according to the
particular needs of the users and application, but in the
illustrated embodiment, the available statuses are "Active" for
boards which are currently utilized by the OEM, "Pre-production"
for boards which are in final approval status by the OEM, that is,
boards which are normally near complete, "Engineering" for boards
which are in a pre-prototype or prototype stage and not yet used in
production, and finally "Obsolete" for those boards that are not
used in any present OEM machines, but which could, for example,
still be made for field upgrades, probably in limited
quantities.
[0083] The "Year" 114 and "Week" 116 fields show the projected
delivery date for the particular board from the CM shown.
[0084] Note that a board can be listed in multiple lines, one line
for each distinct set of, in this example, board name,
manufacturer, status, year and week. For example, in FIG. 3A, the
first three lines show a board having a part number of 200-520-921.
The first line indicates that CM-KK is one of the manufacturers of
this board and is currently building this board.
[0085] The second line shows that a second contract manufacturer,
CM-NN, also manufactures this board, and in addition calls the
board a "Fiber Drtr Board."
[0086] The third line is again for boards ordered from the first
CM, CM-KK, but for a different scheduled delivery week.
[0087] Finally, a footer 118 displays the currently selected
filter, here "Board Type--Active by Board.`
[0088] FIG. 3B shows a pull-down menu 120 which appears when the
user holds down the mouse button over an arrow 107A in the board
column 106. Selecting one of the three menu views displays detailed
information for the corresponding board.
[0089] FIG. 3C shows the displayed view 130 resulting when the "MRP
for ALL CMs" view is selected from the menu 120 for part number
200-520-921, i.e., any of the first three lines of FIG. 3A.
[0090] A split screen, well-known to those skilled in the art, to
allow the display of non-contiguous portions 132, 134 of a view, is
shown. Displayed data includes, for example, "Board" part number
136, "CM" 138, "Board Name" 140, "MRP Date" 142 and "Origin" 144
columns. Board Name corresponds to the same column of FIG. 3A. MRP
Date refers to the date on which the CM must receive parts from the
distributor or the component manufacturer. Origin indicates the
location of the CM's plant where the board is actually being
manufactured (as in Cork, Ireland).
[0091] FIG. 4 shows a view 150 displayed when the "Boards Only"
filter is selected under the "Using EC Parts" in the filter section
104. This view 150 shows data about boards using parts carried by a
particular distributor, in this case IEC. Of course, if there were
more than one distributor, additional filters could be available to
select boards using parts handled by those distributors as well.
The "Board" 152, "Board Name" 154 and "Status" 156 columns
correspond to the similarly named columns of FIG. 3A. If there were
more than one OEM, for instance if the data were being reviewed by
a distributor who deals with multiple OEMs, additional filters
could be available to list boards of particular OEMs.
[0092] Selecting "Boards and Parts" provides an exploded view (not
shown) of boards with additional detail based upon the Bill of
Material, or BOM, for each board.
[0093] The view 160 of FIG. 5A is displayed upon the selection of
the Parts tab 102B. A new list of filters 104B, pertaining to
parts, is available in filter partition 104. Here, the "EC Parts
Demand" filter has been selected, as indicated by its being
highlighted and by the footer text 118.
[0094] As with the parts views of FIGS. 3A-3C, several columns are
displayed, including the OEM's part number 162, the vendor or
manufacturer of the part 166, the vendor's part number 168 for this
part, the vendor's lead-time ("Lead weeks") for this part, the
"Buffer" 172, indicating an amount of inventory quantity, if any,
that has been negotiated between the OEM and distributor/component
manufacturer to be kept on hand above and beyond committed stock, a
"NCNR" indicator 174 which indicates whether the item is
non-cancelable, non-returnable, and a field 176 labeled "Celestica
Part." Each additional CM which manufactures this part has a
corresponding column (not shown), which can be scrolled into view
using the scroll bar 177. Each of these CM columns, such as column
176, shows the particular CM's part number for the corresponding
part.
[0095] Note that customer part numbers, as these are commonly
referred to, are created by the CM or OEM, and have significance
that is beyond the current transactional circle. Thus, a CM may
have a customer part number that may apply to other jobs in
addition to the one they perform for the current OEM. This enables
the CM to sort or use this data "companywide".
[0096] In additional, there may be more than one vendor of a
particular part. For example, the OEM's part number 004-368-101 is
provided by two different vendors, as shown in the second and third
lines of FIG. 5A. Here, the OEM feels these parts are identical and
can be "second sourced" using the same number.
[0097] In fact, lines 5 and 6 of FIG. 5A indicate that two slightly
different numbered parts (e.g., DS1232S/OEM-ZZ and
DS1232S/TR/OEM-ZZ) from the same vendor (VEND-BB) may be used to
satisfy the distributor's part. Each part is shown in its own
line.
[0098] Several filters 104B are provided. For example, sorting is
available for parts profiles for a particular distributor such as
IEC by NAED (a generic industry-wide number assigned by the
National Association of Electrical Distributors), by manufacturer,
or by the OEM's part number or part class. A part class is, for
example, a class of components, such as resistors, perhaps of a
certain wattage.
[0099] Cross reference filters are also available for OEM numbers
and for each contract manufacturer. Finally, parts viewed with a
parts profile can be sorted by "Resale Price", which is the resale
price that the distributor or component manufacturer (the vendor)
charges the CM.
[0100] As can be seen, other filter groups are available, such as
"Lead Times/Buffers," in which parts are sorted, first by lead time
(highest to lowest), then by buffer (highest to lowest), then by
either OEM-ZZ, NAED or vendor part number, as selected. Filters are
organized hierarchically and the upper levels may be closed or
opened (expanded) by the user to simplify viewing.
[0101] Another filter class is Inventory. Inventory levels can be
illustrated by quantity, part type (fully cross referenced), and by
chain participant, i.e., by CM, distributor, or component
manufacturer.
[0102] Yet another filter class is Purchases. Purchases can be
referenced as backlog by the supplier, i.e., the distributor, or a
vendor.
[0103] Selection of the IEC Parts Demand filter shows, going
forward, which parts are due out in what weeks.
[0104] An IEC Parts Admin selection is also available to provide
administrative functions to privileged users.
[0105] As FIG. 5B shows, each line has a corresponding pull-down
menu 180, through which a user can select detailed information such
as "Demand Through Lead Time" or "Demand Through Next Quarter."
[0106] In FIG. 5C, the user has selected "Demand Through Lead Time"
for the OEM's part number 012-000-021, and specifically, the
manufacturer's part number DS1232S/TR/OEM-ZZ, which has a lead time
of 6 weeks.
[0107] Detailed information for this part number is displayed,
including, for example, MRP Origin 192, which has the same meaning
as "Origin" 144 in the screen of FIG. 3C, the contract manufacturer
194 and those OEM's boards 196 which use the OEM's generic part
012-000-021, or, alternatively, boards that specifically use the
vendor's DS1232S/TR/OEM-ZZ part.
[0108] The Week 31-35 columns 198 show quantities related to the
part number, needed for each week for the particular board.
Additional week columns are off-screen, but can be scrolled into
view.
[0109] Totals for each week are shown in the bottom row 199.
[0110] FIG. 6 is a screen view 200 of MRP data by board, obtained
by selecting the MRPs tab 102C. A variety of MRP-related filters
104C are available, providing a large degree of analysis of the
supply chain data. Using these filters, for example, a match
between the OEM's demand and the CM's demand as placed on the
distributor/vendor can be easily shown.
[0111] Here, "OEM-ZZ (C).fwdarw.CM-LL, MRP by Board" has been
selected, indicating a desire by a user to review all boards
ordered from contract manufacturer CM-LL for orders placed on it
by, for example, the branch of the OEM indicated by "(C)".
[0112] The data shown includes each qualifying circuit board part
number 206, the name, if any, given to each circuit board 208, and
quantities 210 for, in this example, each week.
[0113] Similarly, FIG. 7A is a screen view 220 of vendor data,
displayed when the Vendors tab 102D is selected. Various filters
104D, available according to vendor, are selectable. The selected
filter, VEND-DD, is highlighted. Data shown includes circuit board
part number 222, NAED number 226, contract manufacturer CM-KK's
part number 228, a manufacturing part number 230, and the
manufacturer name 240.
[0114] In FIG. 7B, a pull-down menu 242 is available for each OEM
part number, by clicking on the arrow 224 (FIG. 7A) next to the
part number, allowing the user to see all boards using that
part.
[0115] FIG. 8 is a screen view 250 of sales data, which is
displayed when a user selects the Sales tab 102E. A variety of
sales-related analysis filters 104E are provided. In the
illustrated example, "Sales--By NAED Number" has been selected.
Several columns of sales-related data are displayed, including CM
252. The first column 252 is labeled with the name of the OEM, here
"OEM-ZZ". Preferably, each account or location for a CM has a
different name. For example, CM-LL8 is a specific account for
vendor CM-LL.
[0116] Other columns include order number 254 from the CMs to the
distributor, the NAED-assigned part number 256, discussed
previously, the vendor's part number 258, customer part number (PN)
260 corresponding to the OEM's part number and a quantity ordered
262 and quantity shipped 264. Note that the OEM is normally that
entity that has "the customer number".
[0117] A CM Terms Admin selection allows an authorized user to
perform administrative functions. Such functions can serve to
quantify business rules to a CM, including such terms as
scheduling, buffer inventory and liability.
[0118] FIG. 9 is a view of the reports ordering window 270,
displayed upon selection of the Reports tab 102F. A variety of
analysis reports 104F, arranged hierarchically by topic, is
available. Topics can include, but are not limited to, analysis
reports, monthly shipment reports and day sales outstanding (DSO)
reports.
[0119] A selected report can be sent to the screen, to a printer,
to a file, or to a person via email, by selecting the respective
button 272, 274, 280, 286. "From page" and "To" fields 276, 278
allow the printing of only selected pages. File Name and File Type
fields 284, 288 allow the designated report to be named and saved
in a variety of formats. To, cc:, Subject and message fields, 288,
290, 292 and 294 respectively, allow the user to specify recipients
of the report, and to add a subject and remarks.
[0120] Note that in FIG. 9 a lead time analysis report has been
selected in the filtered 104f, and send report to screen 272 has
been selected.
[0121] FIG. 10 is a screen shot 290 of a typical report sent to the
screen for the lead time report requested in FIG. 9.
[0122] The present invention traps conditions that will create
problem situations for the networked partners. When looming
conditions of surplus or shortage become apparent by looking ahead
at supply and demand, an alert is raised by coloring the Alert tab
102G bright red. Of course, in alternate embodiments, a flag or
other icon, or, for example, an audible signal, could be used as
well to indicate alert conditions. The screen 300A shown in FIG.
11A is displayed upon selection of the Alert tab 102G.
[0123] The alert window 300A is divided into two sections. The
upper portion 302 lists current alert conditions by alert type 304,
origin 306, CM 308, the OEM's number for the affected board 310,
the OEM's part number for the actual part causing the alert of
column 312, the manufacturer of the part 314 and the manufacturer's
part number 316.
[0124] The lower portion 318 of the window 300A shows details of
the currently selected alert condition 302A in graphical form. Bars
are preferably color coded. For example, bar 322A could be light
blue to indicate some status, while bar 322B could be green to
indicate another status, bar 322C could be yellow to indicate yet
another status, and bar 322D is red to indicate alert status. Bar
321, indicating lead time, is dark blue. While different colors can
be used, red is preferred for alert conditions to catch a user's
attention. In particular, red preferably indicates trouble on a
lead time for a defined part number. Other colors are for
differentiation of lead-time periods.
[0125] In one embodiment, a bar is red to indicate that a product
is overdue and not received. The left side of a bar indicates when
a product is first due, while the right side of the bar indicates
when all product is due. A green bar, on the other hand, indicates
the period during which product is expected to be timely received.
The left side of a green bar coincides with placement of an order.
If a full shipment is received the entire bar is green. The right
side of the green bar indicates the final receipt of a product.
[0126] Liability windows (LW) are also shown, defining a period of
time within which the distributor will be liable for the
procurement of the subject part if an order is cancelled. This
period is indicated by the width of the LW bar, which in one
embodiment is yellow. If the distributor cancels outside that
timeframe, then no liability exists. Liability windows can differ
among part number and by vendors. When a user clicks on a LW bar, a
number of day(s) of the LW appears in a pop-up window. Since this
number defines the LW, the distributor can cancel any quantity due
without liability if such cancellation is for product due beyond
the right side of the LW bar.
[0127] As this example suggests, an unexpected production plan
increase is impacting the supply chain. Here, the problem week,
week 13 of 1999 as indicated by bar 319, is viewed in relation to
the purchases that have been made for that part. Details of each
bar include, for example, purchases, deliveries, and delays that
can conspire to aggravate a demand condition.
[0128] Individual line items, such as 302A or 302B, can also be
color coded to indicate a particular status.
[0129] Similarly, any of the lines containing boards or part
information, as depicted for example in any of FIGS. 3A-8, can also
be color-coded to indicate status, in particular, an alert
condition. Either the background or the text itself can be color
coded.
[0130] In one embodiment, navigating to the screens depicted in
FIGS. 11B, 11C and 11D is done by clicking the right mouse button
on a blank part of the screen of FIG. 11A. A pop up window appears
(not shown). The user selects "sales" to go to the screen of FIG.
11B, or "quantities" to go to the screen of FIG. 11C or FIG.
11D.
[0131] Also, by clicking on a bar 322D on the graph 318, the screen
300B of FIG. 11B is displayed. This view displays the same problem
event in the context of sales of the product that can yield an
unattainable obligation unless measures are taken immediately.
[0132] In FIG. 11C, the bottom portion 330 of the screen 300C shows
quantity levels for the problem part. Preferably, the different
quantities are color-coded. The available data analysis can make
visible the resulting expected shortage that too often occurs, and
meets with an untimely response that has already broken the
efficiencies of the manufacturing process.
[0133] Current MRP is the MRP data that was last received. Previous
MRP is the MRP information received just before the last. Changes
to the MRP can be viewed here. In this example, the previous MRP
called out for 500 pieces, while the current calls out for 1000
pieces. Thus, a 500-piece shortage has been created.
[0134] On-hand is inventory, and is preferably categorized by each
distributor, the CM's and the vendors. It is important to have
access to all stock positions on an ongoing basis.
[0135] FIG. 11D presents an alternate alert screen view for use in
one embodiment of the present invention. Panel 352 allows a user to
view alerts pertaining only to certain vendors or parts, etc. In
addition, rather than using bars to portray data, a graph 354 is
used.
[0136] FIG. 12 is a graph 400 illustrating the use of animation by
the present invention to present data. The present invention is
based upon state of the art technologies that lend themselves to
analysis and modeling of trends. This affords a novel opportunity
to put the aggregate data to use in viewing the dynamics of the
supply chain.
[0137] The graph 400 can be viewed by selecting an icon in a
toolbar (not shown). By clicking on a "play" button (not shown)
next to the graph 400, the user is presented with multi-dimensional
views of the data, including animations of the data over time,
which enable the discovery of conditions that can be smoothed to
the advantage of all partners in the supply chain.
[0138] In FIG. 12, the sum of orders is negative when there are not
enough orders to fulfill requirements.
[0139] With the analysis tools described above, if a vendor does
not have a sufficient quantity of parts, the distributor can easily
find a CM who has surplus parts to sell to another CM who needs the
parts.
[0140] The present invention provides feedback to CMs and vendors,
pointing out their weak spots, and showing where they can
strengthen their position by cleaning up their data.
[0141] While the present invention has been shown in a
distributor's supply chain, it can also be used anywhere there is a
supply chain, such as in retail, wholesale, the food industry,
etc.
[0142] It will be apparent to those of ordinary skill in the art
that methods involved in the present system for monitoring a supply
chain may be embodied in a computer program product that includes a
computer usable medium. For example, such a computer usable medium
can include a readable memory device, such as a hard drive device,
a CD-ROM, a DVD-ROM, or a computer diskette, having computer
readable program code segments stored thereon. The computer
readable medium can also include a communications or transmission
medium, such as a bus or a communications link, either optical,
wired, or wireless, having program code segments carried thereon as
digital or analog data signals.
[0143] While this invention has been particularly shown and
described with references to preferred embodiments thereof, it will
be understood by those skilled in the art that various changes in
form and details may be made therein without departing from the
scope of the invention encompassed by the appended claims.
* * * * *