A Class I railroad has 14 maintenance plants across the US where locomotives and passenger cars are repaired and maintained. Included in these are 4-5 major 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. The requirements were manually analyzed 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 ultimately translates the material requirements into Supplier Orders for the ERP (Enterprise Resource Planning system). The tool applies the plant schedules, sums all locations, evaluates existing inventory levels and calculates the material to be purchased. Extensive management analysis and reporting is included to facilitate annual funding requests to the FRA (Federal Railroad Administration.) The Capital Program analysis process was reduced from many months to a matter of weeks.