IFM at Mason Companies Inc-VER V-Revised-Inyxa (1)
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Transcript of IFM at Mason Companies Inc-VER V-Revised-Inyxa (1)
Integrated Fulfillment Management at
Mason Companies, Inc.
Ryan Plotz, Sr. Systems Analyst, Mason Companies, Inc.Dan Raffesberger, Sr. Systems Analyst, Mason Companies, Inc.
Oracle Value Chain Summit 2015
Agenda Company Background Initial State Objectives Project Team Implementation Transformation Process Go-Live Success Project Impact
Company Background Founded in 1904 by August Mason and son Bert Mason Family owned, located in Chippewa Falls, Wisconsin
Company Information Top 100 largest internet retailer in the US Marketing channels
Catalog mailings Email marketing Websites
All 10 catalog sites ShoeMall, Ebay ShoeMall, Amazon ShoeMall Ebay Enabba
Logistics 3 Distribution centers High number of purchase order receipts High volume of returns High picking/packing rates
About iNYXA • Chicago-based global Oracle integration Partner
& Software Developer, since 2008.• Focused exclusively on E-Business Suite –
Supply Chain & Manufacturing functions. • Several complex implementations, pre-built
solutions & bolt-on products for customers in Retail, Industrial Manufacturing, Hi-Tech, Healthcare.
• Cost competitive with Global Delivery Capability using Development Centers in India, and an experienced Onsite team.
Select Customers
Operational Consulting
Oracle Product Expertise
Custom Development Capabilities
Project Management &
Execution Excellence
Mason Initial StateOperational Platform Issues:
Highly customized, built for Mason, minimal support/knowledge community
Obsolete technology stack (Mason one of the largest users in the world)
Different technologies for supply chain and financial components
Warehouse control system (automation) integration issuesBusiness Issues:
Business expansion opportunities hindered by current system limitations:
Drop-ship, acquisitions, new/different product linesHowever:
Distribution operations very efficient Met or exceeded industry standards
Transformation Objectives Integrated financials More user friendly/supportable environment Tighter integration within fulfillment systems Eliminated non-supported technologies Enhanced ability to expand into different business
opportunities Transferred legacy sourcing/distribution licensing to other
business areas Reduced legacy risk Improved business self sufficiency/reduce IT dependency for
business tasks
Transformation Process System Selection Process
2011-2012 - All tier 1 vendors evaluated Well defined requirements Extensive sales demonstrations
Phase 1: Implement Oracle Financials Summer 2013
Phase 2: Implement Inventory/Purchasing/WMS Integrated with Product Information Management and
legacy Order Management System Summer 2014
Phase 3: Stabilization Ongoing
Transformation Approach Limit to required supply chain components for
initial implementation phase Use vanilla EBS wherever possible No core EBS customizations – keep upgrade path Maintain legacy system efficiencies where
appropriate All components on one technology stack Unit test individual components prior to
integrated testing Multiple integrated testing events, several rounds
of load testing
Transformation Team Mason
IT/Technical (6) Functional and subject matter
experts (6) Executive sponsor (1)
Inyxa Inyxa solution architect (1) Inyxa functional/technical lead (1) Inyxa development team (7)
Transformation Process Details All supply chain operational areas touched – broad and
deep Impact Special interest and attention:
Very seasonal, fashion-based product Unique attributes for industry and vast product base
400+ attributes stored at 3 different hierarchical levels, with inheritance All Interfaces (STIBO, legacy OM) must be robust Complex purchase orders: 100s of lines with multiple and changing product
types Detailed operational evaluation of receiving, crossdock, putaway, waving,
picking, packing, multis, equipment, returns, cycle count (a lot of time) All standard implementation steps
but very complex due to overall scope of project
Warehouse Implementation Highlights
• We did not start the discussion with what the Oracle WMS system can do, instead we started with what the ideal process for Mason should be.
• Warehouse on legacy system was fairly efficient since sorting / conveyer equipment purchased over the years was optimized with legacy system.
• Goal was to build on the strengths of the legacy system while addressing known limitations.
• Even though several extensions were built, with over 30,000 lines of code written, no customizations were done to Oracle code, making the overall solution upgradeable & patchable.
A dozen Mobile User Interfaces to enable efficient integration with conveyer / sorting equipment & retail centric processes.
ADF – Web based portal that handle the very high reverse logistics volume.
Integration with Parcel Manifesting, Dropship & other marketing systems. Parcel
ManifestingDrop Ship
AggregatorProj
ect H
ighl
ight
s
Planning/Purchasing & Handling Style SKU’s
• A Planning / Purchasing web portal was built to provide a grid interface for purchasing Style SKU’s
– Ability to recommend purchase quantities & react to changing demand projections by highlighting opportunities for pull-in & push-out of supplier delivery dates.
– Ability to seamlessly integrate with EBS Purchasing. Purchase Orders started in custom screen can be completed EBS and vice-versa.
• Real-Time integration with STIBO Retail PIM
– Ability to leverage hierarchical mass item attribute management in PIM and interface it back into EBS in near real-time.
– Ability to handle extremely large data volumes & two way item creations (Open Items crated in EBS and interfaced to PIM)
PIM
Mid
dlew
are
Initial Go-Live Success! Go-live plan very important(~1000 line project plan…)
Conversion and mass loading of Inventory items (over ½ M SKUs)
73K stock locators, and over 1M inventory item quantities and costs for 3 facilities
25K purchase orders Millions of customers Millions of legacy orders (returns) Millions of outstanding prepaid returns Thousands of suppliers Thousands of orders in initial load
More Go-Live Success! Timed with fiscal year end
(June 25th – 29th, 2014) Minimal impact to
business/customers Order management unaffected Warehouse and purchasing only offline 2
business days Resumed normal warehouse/purchasing
operations Monday, June 30th as planned No additional resources required to meet
shipment demands caused by downtime Shipped normal-day volume within
the first 24 hours!
“This is probably the smoothest transition of a major IT system that I have ever seen.”
Daniel J. HuntPresident/CEO
Mason Companies, Inc.
Transformation Results after 6 Months…
Busiest holiday season in company history Shipped millions of packages!
Had highest unit shipping day in history of the company! (and 3 of top 10)
No disruptions to business efficienciesPicking efficiency IncreasedIncreased customer satisfactionExpanded call center – removed legacy license
constraints
Transformation ImpactStrategic transformationReduced legacy riskIntegrated financialsMore user friendly/supportable environmentTighter integration within fulfillment systemsEliminated non-supported technologiesMore efficient business processes – cut out IT middle
manBetter positioned company to pursue new business
ventures
Keys To Success Right people
Good partners Internal resources with the prior Oracle EBS experience Small but focused team Executive support
Right technology Stable release Required core functionality existed Flexibility of APIs
Multiple iterations of testing