A Class I railroad has 14 maintenance plants across the US where locomotives and passenger cars are repaired and maintained. Included are facilities that do Capital Improvements on the rolling stock, including complete overhauls. The Procurement Department prepares its capital funding requirements annually.
Procurement had no automated tools to evaluate the Planned Production Schedules from the Engineering Systems and compile capital purchase requirements. Inventory Planners spent months meeting with directors of the major facilities to obtain capital work projections and corresponding material requirements. Material requirements were manually analyzed using spreadsheets to create purchase orders to suppliers.
Dumas Software automated the entire process by developing a Web Application that imports Planned Bills of Material from the Engineering System and translates the material requirements into Supplier Orders for the ERP (Enterprise Resource Planning system). The tool applies the plant schedules, aggregates demand from all locations, evaluates existing inventory levels, calculates the material to be purchased and creates orders in the ERP. Extensive management analysis and reporting is included to facilitate annual funding requests to the FRA (Federal Railroad Administration.) The Capital Program Planning process was reduced from many months to a few weeks.