Avail is an integrated suite of Supply Chain Management tools created by Areté, Inc. Avail is the latest in a long line of proven Areté products that have been implemented in hundreds of manufacturing sites, plants, and distribution centers around the world.
Avail6 will help your manufacturing facilities to:
- Minimize production line changeovers
- Reduce material batching errors
- Reduce the number of production schedule changes
- Decrease inventory costs
- Substantially reduce out-of-stocks
- Further minimize the risk of stock-out across the source network with the available Safeguard™ Deployment generator, designed to utilize statistical methods based on forecasts and related data
- Improve product rotation and reduce dumpage
- Substantially decrease inventory shrinkage
- Maximize transport loading efficiency
- Improve utilization of logistical assets such as production lines and transports
- Centralize and organize enterprise information
A full Avail system consists of six integrated modules that help plants schedule production, raw materials, material batches, orders and deployments to distribution centers and provide historical inventory reconciliation and variance reporting. These modules share common master data that describes all product-site combinations controlled by Avail and can be installed on several network architectures (application, file or terminal server). The modules can be implemented simultaneously or rolled-out in separate, distinct phases. Each Avail module is briefly described below.
Avail's Production Module helps plan production runs for the right time and in the right quantities. It will identify capacity issues, generate and manage a schedule and produce reports detailing scheduled production and batching activity.
Avail's innovative Production Schedule Timeline offers the ability to schedule production using multiple views with which to evaluate and manipulate the schedule. The Timeline's flexibility allows you to visualize the consequences of several potential production scenarios to determine the best one. Using proprietary sistering techniques, Avail enables you to achieve significantly improved production efficiency by synchronizing the scheduling and quantities of packages that are run simultaneously or back-to-back so that both will run out together.
Deployment Scheduling and the Safeguard™ Deployment Generator
Avail generates product shipments to distribution centers (DCs) to ensure that each DC's inventory remains at or above its Safety Days Supply level while making sure that no DC receives more than its fair share. Proper deployment of product is the key to efficient production scheduling. Avail can generate bills individually, by truck, or for all loads out of a particular location. Avail allows you to dynamically evaluate and modify the deployment schedule. Avail will build bills of lading subject to various constraints and objectives.
New to Avail is the available enhanced Safeguard™ deployment generator designed to further minimize the risk of stock-out across the source network utilizing statistical methods on forecasting error data. The approach of Safeguard deployment is to allocate inventory in proportion to demand. In order to utilize Safeguard functionality, users need to carefully set Deployment Lead Days for each location, a factor which is dependent on travel time, load out windows, and when and how often deployment is scheduled. In addition, instead of setting a System Buffer Days Supply for each product deployed from a plant, Safeguard users need to set the Target Service-to-Sales level. This can be a single number for all products, or users can set product-specific numbers if desired. With Avail Safeguard deployment, planning managers gain valuable assistance controlling inventory levels while ensuring the highest levels of availability for clients’ most profitable products.
When the production schedule is completed, Avail automatically extends the schedule into the future and explodes all scheduled runs through each product's bill of materials to calculate expected future usage. All currently scheduled deliveries are reevaluated against expected usage to determine what action (accelerate, postpone, cancel) is necessary. New deliveries can be generated, bringing materials into the plant on a just-in-time basis.
Full Goods Order Scheduling
Use Avail's centralized Ordering module to place orders according to set delivery horizons for purchased product items from outside co-packers or suppliers. Avail offers the flexibility of rolling up the demand of smaller DCs to the plant, or sending the orders from suppliers directly to the DCs, avoiding the cost of double-handling.
Avail provides three ways of recording inventory counts and transactions. First, Avail automatically converts all entered scheduled production, shipments, and receivers into actual inventory events. Second, you can enter counts and unscheduled production, shipments, and receivers into actual inventory events. Second, you can enter counts and unscheduled transactions such as breakage, dumpage, etc. directly into Avail. Third, most transactions can be imported or merged through the Avail Application Program Interface (API) from external sales settlement systems or hand-helds.
Use Avail's Syrup Scheduling module to schedule and record syrup batches, view and print batching tickets, batch logs, and formula books. The system is set up with the formula for each type of syrup that is batched, including a bill of materials and set of quality control standards such as target brix and pH. Given the code of the syrup, the number of units to make, and the current brix of the sweetener (if used) the system will print a batching ticket with each scheduled batch that details the quantities of all ingredients needed. By calculating quantities of each ingredient automatically, the syrup scheduling module dramatically decreases the likelihood of a costly mistake in the syrup room.
The Right Amount of the Right Product in the Right Place at the Right Time.
Areté Solutions can help you get it Right, by synchronizing your Supply Chain between departments, divisions, countries and with your trading partners.
Benchmarking shows that D&OP improvements carry to the bottom line.
Typical Quantified Benefits from Improving D&OP:
Improve Forecast Accuracy
Lower Total Value Chain Costs
Improve Line Efficiency
Reduce Non-Value-Added Work
Defer Capital Expenditures
16% - 28% Improvement
25% - 60% Improvement
25% - 80% Improvement
10% - 16% Improvement
5% - 10% Improvement
5% - 15% Improvement
25% - 100% Improvement
Based on volume growth
Source: The Gartner Group
Benefits of Areté solutions:
Reduced Inventory Investment - Reduce inventory investment by effectively managing the days of supply of inventory through improved forecasting and efficient production scheduling and deployment. Areté Prevail and Avail are designed to provide the maximum flexibility and accuracy in forecasting while optimizing filler production capacity through constrained-based algorithms. Production output is directly connected to Deployment planning and scheduling to ensure the right amount of product is moved to the satellite warehouses. Avail contains all the algorithms to calculate and manage the days of supply of your inventory both at the plant and in your warehouse network. Five levels of tolerances are used to manage the safety stock to ensure the highest levels of customer service while minimizing overall inventory requirements.
Improved Customer Service - Meet your customer orders at unprecedented levels of satisfaction through improved forecasting and management of inventory. Sales and customer service personnel will have the confidence to commit, while the operation will be able to focus on delivery of the product on time and in the right quantities. Areté Prevail and Avail work in tandem to provide the best opportunities to satisfy your customers.
Effective Collaboration with Customers and Suppliers - Maintain effective collaboration with customers and suppliers through integrated management of inventory, production, deployment, materials and orders. Areté users can be confident of the orders required for delivery of product to customers. Sales and Customer Service will be able to confidently collaborate with customers on their needs and make commitments for orders. Suppliers' orders can be directly relayed via internet, fax, phone, or email.
Reduced Obsolescence - Achieve reduced obsolescence as a direct result of the proper planning and scheduling of production and deployment coupled with sound inventory management safety stock levels. Areté users can be confident that when properly forecasted, produced and deployed, their inventory will be in the right place at the right time and in the right quantity.
More Profitable Promotions - Areté Prevail allows you to pre-plan your promotions and utilize sales history to ensure proper forecasts. These forecasts are used to develop production and deployment plans to ensure that the promotional product will be in the right place at the right time in the right quantities. Coordinate an efficient promotion with the lowest possible supply chain costs.
Reduced Supply Chain Operating Costs - The bottom line result of good forecasting and coordinated and integrated planning is reduced supply chain operating costs. Areté Prevail and Avail give you all of this! Prevail has the strongest forecasting models in the business tied to a collaborative methodology to ensure that the personnel most knowledgeable of the market, the sales personnel, have a strong input into the final forecast. Prevail is the first link in keeping supply chain operating costs down. Avail carries this forecast forward into optimized production, materials and deployment schedules. The final result is the best possible combination of availability at the lowest supply chain costs.
Less Production Expediting - Better forecasts, better inventory management and better deployment all add up to overall process management that reduces requirements to expedite production. Areté Prevail and Avail work in tandem to provide for the overall visibility and accuracies required to keep expediting to a minimum.
Reduced Trans-Shipping Costs - Make trans-shipping of product to balance inventory almost a thing of the past with accuracy in forecasting provided by the collaborative Prevail and optimized production schedules based on the 5 tiered inventory management Days of Supply system of Avail. Avail's hierarchical deployment management process also ensures proper balance of inventory in even the most complicated warehouse networking system.
Smooth Product Launches - New product introductions are smooth and accurate when utilizing Areté Prevail's capability to quickly and easily create histories for new products based on the sales history of similar products
Increased Inventory Turns - The result of initiating the supply process with an accurate forecast delivered by Areté Prevail and following that with optimized production and deployment schedules from Areté Avail, adds up to improved inventory turns and overall reduced supply chain management costs.
In short, Profitability and Shareholder Value go up, while costs go down.
Areté products have been designed from the ground up specifically for the beverage industry. One hundred percent of our solution's functionality is focused on improving and simplifying the process of managing the supply chain. When you purchase Areté products you can be certain that you will use all of the functionality! The user was kept in mind every step of the way in the creation of these tools. Simple, easy-to-use screens combined with graphic visualizations of plans and schedules make these tools the most user-friendly in the industry.
Areté Prevail is based on the idea that a final collaborative forecast is best achieved by starting with solid performing historical causal and time-series statistical models. Once generated, the forecast is transmitted to participating sales personnel to ensure their input. Their knowledge of the most recent changes in the marketplace, weather, and competition are incorporated through Areté Preview. A unique and simple graphical tool allowing sales people to quickly and easily see and adjust the generated forecast. Easy to train and very easy to use, this tool can dramatically improve the final operational forecast.
Areté Avail receives the forecast through an integrated and simple automated interface. Avail is based on the concept of starting with the forecast generated by Prevail along with an up-to-date and accurate inventory count of all finished goods and raw material products. With these critical inputs, Avail will produce an optimized finite and constrained production schedule. Avail’s unique and simple Production Schedule Generator is the most advanced method of producing optimized schedules in the industry.
The Production Schedule Generator gives you a fast and optimized schedule, taking into account all the critical elements of a production line, such as concentrate usage, filler capacity, line speed, minimum run quantities, and others. Combined with Avail’s proprietary visual production timeline screen where the user can easily see scheduled production runs, available and planned inventory, demand and sistered products, the output of the Generator gives the user a fast and accurate means to completing the best possible schedule.
Steps involved in developing the production schedule include the creation of raw materials requirements and orders for purchased finished products using the Materials and Orders Modules of Avail.
The Materials Module provides users with all the required information and means to see current and planned inventory levels, create orders based on published production schedules, shift previously planned orders, and communicate the most current demands to vendors.
The Orders Module is designed to allow those locations that purchase many finished goods products from other vendors to visualize, plan, and order those products. Once an order is placed, the future delivery of the product is placed onto the inventory timeline screens so that users can see the inbound product and plan appropriately.
The Deployment Module of Avail allows the users to create the best possible plans and schedules for moving product from the plants to the warehouses. The Deployment Module visually displays the planned bills of lading with a color coding of products based on their criticality. The Deployment Module is designed to allow the user to make the final decisions on which loads are most critical, which products to use to fill out trucks, and the total number of trucks to deploy. For those bottlers with multiple truck sizes, Avail can create truck specific loads ensuring all trucks are fully loaded and balanced for weight. The user can set all the rules for how the truck is loaded, when it is loaded and finally create a Pick Ticket for the warehouse that gives all the details required for the forklift drivers to properly load the trucks. This final Single Truck Loading functionality can be deployed out on the warehouse floor for the shipping department to utilize as trucks arrive ensuring that the most critical orders are loaded first.
Underlying all of this functionality is Avail’s Inventory Module. With the capability to enter all transactions, visualize current inventory levels by SKU, manage physical inventory counts, and develop a host of inventory reports, the Inventory Module is the critical foundation to Avail.