IGSA LABS

Leading Supply Chain Optimization Solutions

About IGSA

IGSA (Integrated General Systems Analysis) Labs offers solutions based on mathematical optimization models

for supply chain strategy, planning, and execution

Our versatile solutions are tailored to the clients specific requirements

Procurement Network Design & Order-Vehicle DemandPlanning Integrated Order &

Planning AllocationPlanning Assignment& Route & Replenishment SupplyManagement
Planning

Our Customers

Cem ent

Other
Sector
+ Other

Academic
Association
solutions in
detail
Network Allocation
Netw ork Allocation Planning
Planning & Design
& Design (MLP & FIP)
(MLP)

Plant-1

Warehouse-1 Distributor

Plant-2

Warehouse--2
Retailer
Plant-3

Warehouse-3

Plant-4
Modern Trade

Plant-5
Warehouse-4

Other Customers
Plant-6 Direct Movement-1

M LP

Key Inputs Key Outputs Key Decision Supports IT Integration

Monthly forecasted demand, Allocation Plan -Optimal -Masters

sales price & Gross price from Plants to aggregate and
- Plant level product Dealer/Distribut production plan logistics
capacity or:
-Optimal cost
- Variable Production Cost - Plant to Dealer
- Plant to inventory plan -Price/price
- Plant to warehouse freight -Optimal index
Warehouse
&
- Rake to distribution
handling cost
Warehouse plan
- Plant to Dealer freight & - Warehouse to
handling cost Dealers
- Warehouse to Dealer
freight & handling cost
Analysis and Decision MLP can support

Daily Order- source allocation planning to Strategic analysis

Execution Level Daily Monthly Planning Strategic Planning

• Sales orders optimization • Green f ield / Brown f ield

• Production m ix planning expansion analysis
• Plant sales
• Logistics allocations • Production mix analysis
• Depot sales Stock transfer
orders
• Sales planning • Geo mix analysis

• Invoice compliance
•Total cost to serve / • Budget plans
analysis
contribution
• Mode mix analysis
• Invoice route verses optimal • All costs paths for orders
route compliance execution
S & OP Planning

Connecting teams and plans across your Business

Production
Marketing
Team
Team

IGSA
Logistics Optimizer Finance
Team
S & OP Planning Team

Sales IT
Team Team

Collaborative Supply Planning & Execution

• Assists in preparing long-term (One-year Visible Plan) and short-term (Three-Six visible Plan) goals

• Create, analyze and evaluate various “What-If” scenarios to optimize your plans and create a solution-centric

supply chain plan with your team

• Update supply chain planning models as the market demand changes

MLP Active Client Engagements

Cavin
Cement Clients Adani Britania Mahindra ACC ACL Orient SCL/GSCL Chettinad Emami Lafarge
Kare
Network Redesign

   

Budget Planning 
  
Monthly Rolling Planning
       
Compliance Analysis
       
Integrated sales order
planning with L1/L2/L3 reports
for daily dispatch planning    

Procurement Planning  
 Case Study: Production & Logistics Planning at large cement company
Challenges:
Monthly Planning : Balance the demand and supply and arrive at a optimal plan
Combing the different plans (production, sales, and logistics ) & arrive one
common plan as an objective
Solutions to build several what-if scenarios and arrive a optimal budgetplan

Network Scope: 21 manufacturing locations

More than 300 depot locations
Pan India presence and more than 10000 dealers ( demand points )
W a t e r fall analysis
Solutions: IGSA implemented MLP for client-specific network planning constraints

Integrated optimal production, sales,

logistics & dispatch planning
Actual sales compliance analysis

Results: Total contribution increase by 3% to 15%

Total cost to serve reduced by 5% to 20%
Network Planning Model
Increase in monthly plan compliance by 10% to 20%
Business benefits with MLP

Production Sales What-if

scenario
to
increase
Plants Depots Markets Topline

Service Level Monitor

Production + Logistics Cost
Bottom-
line

Stock transfer vs Direct Ratio/ Optimal inventory levels

Order-Vehicle Assignment & Route Planning (OVAR)

Order-Vehicle Assignment and Route Planning (OVAR) is a solution to optimally assign customer orders

to vehicles and plan routes for the vehicles in a dynamic manner so as to meet customer orders in

time, maximize utilization of vehicles and minimize cost of transportation. It creates value in the

supply chain by synchronizing all your critical transportation processes.

Benefits
Key Capabilities Increase operational
efficiency Decrease cost of
transportation Maximize
vehicle utilization Meet
Daily plan of routes for dispatch of products
time slot based delivery
from
commitments
plants/warehouses to customer

locations Generates mix of milk run

routes

KPI reports: total transportation cost and its

break- down, vehicle utilization, on-time

deliveries, delays and their break-ups

Order-Vehicle Assignment & Route Planning (OVAR)

Multi-Run Courier

M ilk- Run Courier

M ilk- Run
Courier

Single-Run

M ilk- Run

M ilk- Run
M ilk- Run
Single-Run

Key Inputs Key Outputs Key Decision Supports IT Integration

-Real time -Order-vechile - Optimal route plan

customer orders assignment with dispatches in - Orders
-Delivery route and courier/part truck - Vehicle
-Available vehicles
availability
-Serviceability sequence load/milk run
- Tracking
Norms -Vechile utilization dispatches (return to
- POD
-Order fulfillment orgin)/ multi-point
dispatches (no return to
orgin)
OVAR For Order Tracking and Execution

OVAR
- Order-
tracking
-POD/
Order-1 Notifications
Mobile-App -Delivery
status

Order-2

Constraints

-Order specific
-3pl Contracts
- Safety and
Order-3 logistics norms
-Material
Courier Courier Norms
Orders Consignment
Data
Procurement Planning

Markets

Supplier-1

Distributors

Manufacturing Plant
Supplier-2 Retailer

Modern
Trade

Supplier-3 I

Challenges IGSA Optimizer

Provides Monthly Minimizes total landing

allocation of cost (Sourcing cost of raw -
raw material and parts material and logistics cost )
from supplier facilities to Strategise optimal share of
customer facilities business
Strategize Share of Generate optimal raw -
Business (S0B) material inventory report
Demand Planning & Replenishment

Key Inputs Key Outputs Key Decision Supports IT Integration

-Plant/warehouse -Meet order service Warehouse order

-Plant/warehouse
opening/closing level Optimal inventory
-Maximize stock
stock order
inventory turns (or -Forecasted demand
-Service level optimal target stock
minimize -Masters/transactions
-Production/Transit
inventory levels) data
lead time
-Enhance freshness of
stocks
Meet vehicle
utilization norms
Key Achievements with IGSA Optimization

Cost reduction by
utilizing optimal
resource planning &
Replenishment

Minimize overall
Efficient network
transportation costs
design and reduce
by optimal planning &
overall costs
execution of logistics

Optimizer

Increase production
S & OP and align
operational efficiency
business plan as a
by optimal resource
team
use of production-mix

Simplify your Planning and Execution with IGSA Optimization Cloud

Services
Tool Architecture

Input from client server

through Web service CPLEX Optimization
Engine
Input through UI

Data GAMS
Validation Optimization
File
Modeling Generation
Options & Oracle
Constraints

Outputs and GAMS Results SQL

Reports &
KPI’s
Validation Loader Reports (CSV
format)
Results and What-If
–Analysis with UI
Out put to client server
through Web service
Value-Addition to your Business

Planning-Level

Production Planning Logistics Planning Sales Planning

Procurement Planning
- Strategize SOB of - Monthly aggregate - Mode Mix planning - Geo mix planning &
production planning Direct vs. STO Planning decisions
Vendors
- Alignment with - Primary dispatch plan - Contribution target
- Identify bottlenecks
growth plans - Secondary dispatch based Sales Plan
plan - Budget Plan

Execution-Level

Last-Mile Distribution Optimization

Engagement Approach

Enable IGSA End-End Supply Chain Cloud Optimization Solutions

Flexible IGSA Cloud Depoloyment Solutions Can be Tailored to Business Requirement

On Cloud SaaS- In Premise Deployment

(Software as a Service)

W e b – se r vi c e s f o r p u l l a n d
W e b – se r vi c e s f o r p u l l a n d p u sh
p u sh o f i n p u t d a t a a n d
of in p u t d ata an d ou tp u t d ata
o u t p u t d at a fro m
f r o m SA P / O t h e r t o o l s
SA P / O t h e r t o o l s

C l o u d C o n fi g u rat i o n
D e p l o ym e n t i n

th e c om p an y

e n vi r o n m e n t
U se r - t ra i n i n g &

r e so u r c e su p p o r t
U se r - t r a i n i n g &

r e so u r c e su p p o r t
 Q &A

THANK YOU