Cycle Time Reduction for POs Processing in Commercial Data Warehouse
Project ID | turbostrive-ISAC-2014-4758 |
Green Belt | G Gayatri Soumya (86019) |
Black Belt | Rajaram G (RG00327136) |
Master Black Belt | Nanjunda Swamy (127049) |
RM | Sarada Rao (27446) |
Sponsor | Neal Jacob (952) |
Project Summary
Business
Problem
Statistical
Problem
Statistical�Solution
Business
Solution
- Per Feed > 24hrs (41 Feeds per Quarter ) Multiple iterations do be done until the final feed is with proper customer details. ( On an average 8 Weeks to complete the E2E cycle )
Project Summary
Project Name : Commercial Reporting Project ID : 13001040
Executive Summary
DEFINE
Voice of Stakeholders
Associate
What they said ? (Voice of Associate) | What they meant ? | ||||
What is the Need ? | When is the Need felt ? | Where is the Need felt ? | Why is the Need felt ? | How is the process now ? | |
Huge amount of manual efforts are involved in processing purchase orders since all businesses are not able to send the Orders in a standard format. | To process the Purchase Orders within 24 hrs. and report and to avoid manual efforts | When feed is bulk and manual efforts consume long time due to more number of rejections. | Need felt while processing the Purchase Orders and validating the rejections. | To provide the synchronized Purchase Orders DWH report to users in business hours | Currently Purchase Orders are processed Manually and tested in QA environment for validation of rejections because of which each feed takes >24 hrs. to process. |
Cycle time of entire PO processing is high since Purchase Orders are being sent by multiple business from different time zones and location. | Purchase Orders to be reported on the same day as and when they are received irrespective of time of arrival from Business | When users from multiple businesses send feed during different time zones and when team not available. | While Production loading window consume more time. | To make the DWH Sales/Orders reports available to Business for calculation of VC for sales executions on quarterly basis. | Currently Cycle time and Loading window is high since feeds come from different Businesses and in different time zones. |
What they said ? (Voice of Investor) | What they meant ? | ||||
What is the Need ? | When is the Need felt ? | Where is the Need felt ? | Why is the Need felt ? | How is the process now ? | |
The DWH should be enough robust and transparent for functional users to handle the customer needs and set a way to handle multiple businesses | Improve the goodwill of the DWH to business client | When customer is having dissatisfaction and asking for an better DWH | Report Availability for Finance team during calculation of salary (VC) for sales executives | To provide better solution to customer | Its good but not the best |
Investor
Voice of Stakeholders
What they said ? (Voice of Customer) | What they meant ? | ||||
What is the Need ? | When is the Need felt ? | Where is the Need felt ? | Why is the Need felt ? | How is the process now ? | |
Need a transparent tool to process the PO’s at any point of time and reports should be delivered on the same day. | For calculation of incentives in salaries of sales executives | When Purchase Orders are not received before final payroll cut off date. | To retrieve the DWH reports with synchronized data for all businesses within same day of PO arrival | Incentives getting impacted and users not able to view top customers information | Process not capable to deliver all business PO’s to users within required time period while accessing feeds from different time zones.(Business- Power & Water, Oil & Gas) |
Customer (General Electric Inc.)
Society
What they said ? (Voice of Society) | What they meant ? | ||||
What is the Need ? | When is the Need felt ? | Where is the Need felt ? | Why is the Need felt ? | How is the process now ? | |
NA | NA | NA | NA | NA | NA |
Voice of Stakeholders
S No | Voice of Stakeholders | Process / Service Attribute (refers to the AICS voice) | Need Statement �(From A-I-C-S Perspective) | Delight Parameter (Project y) |
1 | Cycle time of processing purchase Orders is high which is causing delay in calculation of incentives and effect salaries of GE sales executives. disturbs the budget allocation if incentives are carried forwarded to next month due to delay. | Delay in delivering Purchase Orders Data Warehouse (Reports) during quarterly ETL Load | Availability of Orders information for calculation of salaries | Reduction of cycle time of PO processing for On time calculation of salaries /incentives |
Translation of Voice of Stakeholders
Project Charter
Hence, the project needs to be initiated to reduce the Cycle time of PO processing and Reporting to business users and thus to provide a better solution to business.
Business Case
Project Charter
End to End load cycle for Purchase Orders reporting takes 8 weeks ,thus impacting incentive calculations.
Objective is to reduce cycle time to 50%. (8 weeks to 4 weeks)
Problem Statement
Goal Statement
Project Charter
Team Members Names | Roles & Responsibilities |
G Gayatri Soumya | GB Trained team member. |
Ankita Bhatia | Dev Team member |
Dayananda Una | Dev Team member |
Shanker Ravi | Production Support Team member |
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Key milestones/Team Roles
Macro Level Process Map
Supplier
Input
Process
Output
Customer
I
O
S
P
C
Unprocessed Purchase Orders from 20 Sub Businesses of GE P&W and O&G Businesses
Transactional Orders from each Sub Business ERP system.
Processing and Loading Purchase Orders into Operational Store(ODS)
Purchase Orders are updated in DWH and Reports are available for end users.
General Electric Inc.
Start
PO’s are manually processed and loaded in Quality Analysis environment. Then loaded in Production environment
Data loads into Staging Area
General Accounting Procedures/Business rules are applied and loaded into Commercial DWH after validation
Reports are refreshed with Purchase Orders details in DWH and sent to Functional team for Incentives/VC calculations
Stop
SIPOC Diagram
MEASURE
Data Collection Mechanism
41
Daily ( Quarter end activity)
Number of Data Points
Frequency of Data Points
Analysis Method
TechM Internal
Continuous
Type of Data
1.53
Baseline ST Sigma Level
Data Analysis
TechM Internal
DPMO Calculation
No of Defects : 20
No. of units processed: 41
No of OFE: 1
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Defects per Million Opportunities | = | Number of defects found at any check point | X | 1,000,000 | ||||||
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| Number of Units processed | X | Number of oppurtunities of Error |
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Hence ,�� DPMO = 20 1,000,000 = 487805
----------- * � 41* 1
Using the Sigma tables, we can conclude that the Sigma value is 1.53
Defect : Data Feeds breaching SLA of 24hrs ��
ANALYZE
As-Is Value Stream Map
Analyze
Step 4
PO’s
Requested
Customer
5Min
Customer
PROCESSING
TIME
.
Manual
Processing
of PO
Identify
Raw feed
Screen
Door/QA
Process
Ticket
Assigned
Ticket
Logged
For Prod
QA
Testing
User
Verifies
POs
Provides
Approval
W
W
W
W
W
W
W
W
W
150Min
240Min
20Min
330Min
30Min
5Min
10Min
15Min
WAIT
TIME
15Min
30 min
30 min
15min
15min
15min
5 min
10 min
POs
Processed
Reports
Delivered
Manually
480Min
15Min
10 min
15 min
W
W
Non value added activity
Value added activity
Value enabling activity
Team Member
Support Member
Functional User
Datawarehouse Load
Process Value Link Example
Analyze
Step 4
Analyze
Waste Category Identification
(This is not a continuation of example from previous slide)
VA:VE:NVA= 2:34:64
Step 4
VA(2%)
VE(34%)
NVA(64%)
Analyze
Waste Category Identification
VE-Value Enabler: Identifying Screen door rejections
T-Transportation : Manually Ftp feed to UNIX server, KM Portal.
All feeds are manually uploaded by customer ,downloaded from the library by team and tested files are manually uploaded in server and reports are uploaded in library
M- Motion: Logging tickets :-
Tickets logged, assigned, approved manually.
W- Waiting: Wastage of time:-
Waiting time to run the process , tickets to be assigned, executed in production, manual report extraction
O- Over Processing: Rework
Purchase orders are tested in quality analysis environment due to Rejections in source feeds and final numbers are validate by team and functional users before proceeding to production
D- Defects: Rejections in Purchase Orders
Purchase orders are reprocessing due to Rejections in source feeds. This indicates poor data quality
Step 4
Cause and Effect diagram
High Cycle Time for
PO Processing
Tools/System
Environment
Process
People
Ask “Why?”
Fishbone Diagram
Delay in Arrival of POs from Power & Water
And Oil & Gas Businesses
Huge Volume of Data Update at source
Transactional Order get rejected and reprocessed again
Data is sent by multiple businesses – Water, Aero, Gas Engines, Turbo Machinery etc.
Each ERP feed is generated from
different
applications
Due to GAP rules (General Accounting procedures)as per business requirement
Load is taking long time
Low throughput
Load Failure due to Source feed
Recurring load due to rejections
Temp space Full/ Lack of temp space
Data Issue
Database Issue
Database Table Locks
Incorrect Source Data
Load Failure based on target
Dependency on Multiple teams
Root Cause Analysis of any data mismatch
Manual Effort
ERP Source Teams Dependency
Support and Admin Team Dependency
Ticket logged to Support Team. They Work as per SLA
QA Load is to validate
rejections in data
Inaccurate/invalid data
Prod load wont contain rejected PO’s
Rejections if present need to be deleted and reloaded
Multiple Environments(QA/Prod)
Planned/Unplanned Outages
maintenance activities /Network Issues
Planned DB/ETL outages / Unable to connect servers
Manual Process consume more
Time in processing huge volume of Purchase Orders at one go.
Current process consumes manual efforts in converting source feed into standard format
Cause Level 1
Cause Level 2
Cause Level 3
Cause Level 4
Less feasibility by ERPs to generate PO information in standard format
Lack of Communication & coordination
Priority Matrix
Major Cause 1 | Cause 1 | Cause 2 | Cause 3 | Cause 4 | Team member1 | Team member2 | Team member3 | Team member4 | Total |
Tools / Systems | Load taking long time. | Low Throughput | Temp space Full/ Lack of temp space |
| 2 | 3 | 2 | 3 | 10 |
Load failure due to source | Data Issue | Incorrect Source Data | | 2 | 3 | 1 | 1 | 7 | |
Load Failure Based on Target | Database Issue | Database table Locks | | 1 | 2 | 1 | 1 | 5 | |
Major Cause 2 | |
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Process | Delay in Arrival of POs from Power & Water And Oil & Gas Businesses | Each ERP feed is generated from different applications | Less feasibility by ERPs to generate PO information in standard format | Current process consumes manual efforts in converting source feed into standard format | 5 | 5 | 4 | 4 | 18 |
Transactional Order get rejected and reprocessed again | Due to GAP rules (General Accounting procedures)as per business requirement | | | 3 | 3 | 2 | 2 | 10 | |
Huge Volume of Data Update at source | Data is updated for multiple businesses – Water, Aero, Gas Engines, Turbo Machinery etc. | Manual Process consume more Time in processing huge volume of Purchase Orders at one go. |
| 5 | 5 | 4 | 4 | 18 |
Note: Higher the rating, Higher the impact on High Cycle time of PO Processing
Priority Matrix
Major Cause 3 | Cause 1 | Cause 2 | Cause 3 | Cause 4 | Team member1 | Team member2 | Team member3 | Team member4 | Total |
Environment | Multiple Environments(QA/Prod) | QA Load is to validate rejections in data | Inaccurate/invalid data |
| 1 | 1 | 1 | 1 | 4 |
Multiple Environments(QA/Prod) | Prod load wont contain rejected PO’s | Rejections if present need to be deleted and reloaded | | 1 | 2 | 1 | 1 | 5 | |
Planned Outages /Unplanned Outages | Planned DB/ETL /Unable to connect servers | Network Issues | | 2 | 2 | 2 | 2 | 8 | |
Major Cause 4 | |
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People | Recurring load due to rejections | Root Cause Analysis of any failure | Manual Effort | | 2 | 3 | 2 | 3 | 10 |
Dependency on Multiple teams | Support and Admin Team Dependency | Ticket logged to Support Team. They Work as per SLA | | 2 | 3 | 2 | 3 | 10 | |
Dependency on Multiple teams | ERP Source Teams Dependency | Lack of Communication & coordination |
| 2 | 3 | 2 | 3 | 10 |
Note: Higher the rating, Higher the impact on Outage/downtime
Cause and Effect diagram(Vital ‘X’s identified)
High Cycle Time for
PO Processing
Tools/System
Environment
Process
People
Ask “Why?”
Fishbone Diagram
Delay in Arrival of POs from Power & Water
And Oil & Gas Businesses
Huge Volume of Data Update at source
Transactional Order get rejected and reprocessed again
Data is sent by multiple businesses – Water, Aero, Gas Engines, Turbo Machinery etc.
Each ERP feed is generated from
different
applications
Due to GAP rules (General Accounting procedures)as per business requirement
Load is taking long time
Low throughput
Load Failure due to Source feed
Recurring load due to rejections
Temp space Full/ Lack of temp space
Data Issue
Database Issue
Database Table Locks
Incorrect Source Data
Load Failure based on target
Dependency on Multiple teams
Root Cause Analysis of any data mismatch
Manual Effort
ERP Source Teams Dependency
Support and Admin Team Dependency
Ticket logged to Support Team. They Work as per SLA
QA Load is to validate rejections in data
Inaccurate/invalid data
Prod load wont contain rejected PO’s
Rejections if present need to be deleted and reloaded
Multiple Environments(QA/Prod)
Planned/Unplanned Outages
Planned DB/ETL outages / Unable to connect servers
Manual Process consume more
Time in processing huge volume of Purchase Orders at one go.
Current process consumes manual efforts in converting source feed into standard format
Cause Level 1
Cause Level 2
Cause Level 3
Cause Level 4
Less feasibility by ERPs to generate PO information in standard format
maintenance activities /Network Issues
Lack of Communication & coordination
Priority Matrix
Potential Root Causes: Justification –
We are considering rating 10 and above for the analyzing of Potential root causes.
Major Cause | Final Root Causes | Total Rating | Vital X | Justifications |
Tools / Systems | Temp space Full/ Lack of temp space | 10 | Y | |
Process | Current process consumes manual efforts in converting source feed into standard format | 18 | Y | |
Due to GAP rules (General Accounting procedures)as per business requirement | 10 | N | We don’t have any control over business requirements, hence not being considered for improvement, currently | |
Manual Process consume more time in processing huge volume of Purchase Orders at one go. | 18 | Y | | |
People | Manual Effort for Failure recovery | 10 | N | We don’t have any control over failure recovery process and can not ignore manual efforts to get the root cause analysis done; hence not being considered for improvement, currently |
Source Team Dependency | 10 | N | We don’t have any control over the source system and source team; hence not being considered for improvement, currently | |
Ticket logged to Support Team. They Work as per SLA | 10 | Y | |
IMPROVE
Feasibility and Effectiveness Matrix
S.No | RootCause | Solution | Feasibility(F) | Effectiveness(E) | F*E |
1 | Current process consumes manual efforts in converting source feed into standard format | 1. Build an UI tool which enables users to validate mandatory information in the Purchase Order raw Source feeds | 2 | 4 | 8 |
2. Build a single common loading window for all the raw business source feeds which converts into standard format. | 4 | 5 | 20 | ||
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2 | Manual Process consume more time in processing huge volume of Purchase Orders at one go. | 1. Eliminate manual efforts by automating the validations | 4 | 3 | 12 |
2. Setup rejections check in prod prior to load to avoid loading in QA environment and build a auto correction setup for users to correct data | 4 | 5 | 20 | ||
3. Improve the performance of production loading window | 1 | 4 | 4 | ||
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3 | Temp space Full/ Lack of temp space | 1. Minimize the other business loads and utilized spaces as this is a shared environment | 2 | 3 | 6 |
2. Set up a dedicated Database and server environment with enough space | 1 | 3 | 3 | ||
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4 | Ticket logged to Support Team. They Work as per SLA | 1. Dependency on support team should be eliminated | 3 | 3 | 9 |
2. Users should be able to trigger the load whenever they wanted with a UI tool | 2 | 3 | 6 | ||
3. Technical and Functional Training should be given to users and monitoring team | 4 | 2 | 8 |
Action Planning
S. No | Root Cause | Solution | Action Plan | Responsibility |
1. | Current process consumes manual efforts in converting source feed into standard format | Build an UI tool which enables users to validate mandatory information in the Purchase Order raw Source feeds |
| ODS DWH Dev Team |
2. | Manual Process consume more time in processing huge volume of Purchase Orders at one go. | Setup rejections check in prod prior to load to avoid loading in QA environment and build a auto correction setup for users to correct data |
Action Plan Matrix
Note: Currently, considering the F*E > 15 for action plan and implementation as these are having the maximum effect and controllable and achievable inside our project team’s scope.
Earlier vs. Improved Process
Improved Process Map
Using UI tool, functional users validate PO information
Purchase Orders loaded via ETL into CDW DWH
Reports are automatically sent to Users via mail
Calculation of Incentives for GE sales executives
GE Payroll team
Earlier Process Map
Raw Purchase Orders Manually processed
Formatted PO’s are loading in QA for validation
With an Approval, logged ticket to load in Prod
Purchase Orders loaded via ETL into CDW DWH
Reports are manually extracted and delivered to users
ETL load
Cognos Report Studio
Manual Process
Manual Process
Calculation of Incentives for GE sales executives
GE Payroll team
Cognos Report Studio
Rejections Fixed if any
FMEA (Failure mode and Effect analysis)
Process Steps | Potential Failure Mode | Potential Effects of Failure | Sev. | Potential causes of Failure | Occ. | Current Design Controls | Det. | RPN | Recommended actions | Responsibility | Status | Sev. | Occ. | Det. | RPN |
Purchase Order Raw source feeds are validated using UI tool | Failure while uploading feeds into UNIX server | Impact in starting etl load if complete feed not transferred to server | 7 | Due to any network/environmental issue or any data issue | 5 | UI will upload the source feed to Server which triggers ETL load | 4 | 140 | Automated mail should trigger to functional users who uploads the source feed along with count of records | CDW DWH Dev Team | Implemented | 4 | 1 | 8 | 32 |
Failure in timely recovery process | Impact in next incremental load schedule | 7 | Due to multiple team dependencies | 3 | Recovery window should be executed by Support team in case of any failures in servers/etl loads | 7 | 147 | Functional users get failure notification and they contact Support team for fixing the Production server issues | CDW DWH Support Team | Implemented | 5 | 3 | 6 | 90 | |
Data Loading in to Data Warehouse triggers one after other as per dependency Order | Failure during any of dependency load | Impact in next load | 7 | Due to any rejections, trigger file not available etc. | 5 | There will be a trigger file at the end of each load which kicks off next load | 4 | 140 | Automated mail should trigger to the respective support team members for resolution after every load to know the status | CDW DWH Dev Team | Implemented | 4 | 1 | 8 | 32 |
Handle rejections and corrections | Any data issues | Data load will be impacted and users will be affected | 7 | Rejections/corrections in data | 3 | Extract would be sent to functional users for validation | 7 | 147 | If any corrections required, users should be able to correct in the same extract and trigger the load again. | CDW DWH Support Team | Implemented | 3 | 2 | 5 | 30 |
Action Planning(Modified)
S. No | Root Cause | Solution | Action Plan | Responsibility | Target Date |
1. | Current process consumes manual efforts in converting source feed into standard format | Build an UI tool which enables users to validate mandatory information in the Purchase Order raw Source feeds |
| ODS DWH Dev Team | |
2. | Manual Process consume more time in processing huge volume of Purchase Orders at one go. | Setup rejections check in prod prior to load to avoid loading in QA environment and build a auto correction setup for users to correct data |
Action Plan Matrix (Modified)
Note: Currently, considering the F*E > 15 for action plan and implementation as these are having the maximum effect and controllable and achievable inside our project team’s scope.
Communication towards the Business Users
User Guidance
General Guidance to Business Users
# Guidance on UI tool is described on the instructions tab of the UI Macro which is user friendly.
# The CDW Data Warehouse is scheduled every 30mins which enables the users to rerun the loads in case of any rejections or corrections.
Note: Help Guide is provided to Users
CDW– Available Load Timings
Except ETL Dependant Load time:
# Dependant DWH DATA REFRESH would be done on Sunday which loads global customer data. So, functional users are not supposed to run during this time.
During ETL Daily Load /Outage time:
# CDW DWH would have planned and unplanned outages due to network/DB issues and users get notification not to run any loads during outage time.
Load Status mail notification enables users to have transparency on the loads running at backend ETL
Green –No loads in place – During scheduled loads of different dependant schema refresh.
Orange – During Outage time. Users not supposed to run to avoid load failures
Implementation Planning
Implementation Plan/Pilot Design
ERP source feed
Download source file to system
User runs required home appliance tool (Macro button) to convert source file to Unix compatible file
ETL /UNIX Scripts
AUTOMATION WORKFLOW
Converts to text tab delimited
Brings all different files
to common format
ODM
If no rejections,
then load in Prod
(ETL loads)
Extract sent to business for validation
CORRECTION LOAD
ETL Load to
pull loaded
Orders information
If any Orders need to be reprocessed
Users/Support team notified for rejections by emails
Orders are corrected in source files
Sign off
New Value Stream Map
Control
Step 10
Customer
Customer
I
PO’s are placed
in server and
Process is kicked
automatically
W
Purchase Orders
Are processed
if is valid, else
Users get alerts
With rejections
Reports are
Automatically
Sent to
Customers
W
15 Min
360 Min
5 Min
0 Min
0 Min
PROCESSING
TIME
WAIT
TIME
Non value added activity
Value added activity
Value enabling activity
Team Member
Support Member
Functional User
Datawarehouse Load
If load
failures
Alerts via mails
Value Stream Before and After
Control
Step 10
Cycle Time
Before
After
Identify
Raw feed
Screen
Door
Process
Manual
Processing
of PO
User
Verifies
POs
Provides
Approval
Ticket
Logged
For Prod
Ticket
Assigned
PO’s
Requested
Cycle Time
PO’s are placed
in server and
Process is kicked
automatically
Purchase Orders
Are processed if is valid, else Users get alerts
With rejections
Work Time (value add)
Wait Time (non value add)
Relentless Focus on Reducing non value adding activities
Min. 15 360 5
= Total 1460 Min.
= Total 380 Min.
QA
Testing
Reports are
Automatically
Sent to Customers
Same work completed in less time !!
Min. 20 180 270 35 345 45 10 20 25 495 15
POs
Processed
Reports
Delivered
Manually
Monitoring Techniques/Alert Mechanism
Improved Process Acceptance
Customer Satisfied
Thank You!!!