On-time delivery and optimal production require an efficient order management system. From initial order request to fulfillment, order management for KSB's product line of GIW® slurry pumps follows a clearly defined and highly coordinated process. At the helm of order management is Tammy Hubert. To better understand how the process works, one simply needs to consider air traffic control. The efficient scheduling and direction of the order management system is comparable to the scheduling and direction of an air traffic controller. It’s a sophisticated dance of managing incoming orders, stock transfer, and expedited requests, while also coordinating pump building, delivery documentation, and service center support. Let’s take a closer look at how the process works.
Order in
Orders are received via three distribution channels: the project management team for new pump orders, the customer service team for spare part orders, and the service team for service orders. New orders are dated with a confirmed lead time that order management commits to filling the customer's order. This date is used to measure and validate on-time delivery. “Over the past several years, our on-time delivery metric has greatly improved due to increased operational excellence,” Ms. Hubert said. Operational improvements can be seen in not only order visibility but also better inventory management and optimization in the foundry and machine shop.
Orders are then assigned a spot on the flask calendar based on delivery dates and anticipated demand. The flask calendar marks the first stage of production. The master scheduler assigns the orders on the calendar, signaling the foundry when it’s time to start producing a part. There are four value streams of demand that influence their placement on the flask calendar: sales orders, order reservations, forecasts, and safety stock. With this system in place, orders are scheduled for fulfillment in an efficient and reliable manner.
Order up
Slurry pump orders that are ready for production start in one of three foundries located in Grovetown and Thomson, GA. Each foundry can pour up to 70,000 kg and has a casting range of 45 kg to 27,000 kg). KSB’s white iron alloy is abrasion- and corrosion-resistant, and undergoes heat treatment and cryogenic processes for improved wear, corrosion resistance, and mechanical strength.
For precision machining, there are two dozen computer numerical control (CNC) machines and five manual machines that operate continuously. These machines allow for close margins, which leads to superior products. “Our most recent CNC installation, the AC26 machine by Pietro Carnaghi, reduces setup on large shells by 50% because of its multi-axis head,” Ms. Hubert explained.
After machining is complete, the parts are painted and assembled on-site. Then, it’s only a matter of delivering the pump.
Order out
When production is completed, order management turns over the product to the shipping team to fulfill the customer’s order. This process involves several steps, including picking the product, packaging it, creating the necessary shipping documents, and contacting freight forwarders. These steps ensure the correct order arrives at the correct place before the lead-in time. Proper shipping is vital to the success of an on-time delivery.
A great deal of effort has been made to streamline the order management process for slurry pumps, and the results have been well worth the effort. Increased operational efficiency certainly helped, but it’s the dedicated team members who have driven the improvements. Ms. Hubert said, “It is truly a team effort. Order management is a fast-paced environment and provides a unique opportunity to be involved in almost every aspect of an order. I love seeing our parts loaded on trucks, shipping to customers all over the world. And knowing that we played a part in making that happen is very rewarding!”
Learn more about KSB and GIW® Slurry Pumps at www.ksb.com/en-us.