Case Study

Case Study

Overview
KPIT helps PL Developments support rapid growth and meet customer
needs by optimizing supply chain and warehouse management
Customer Overview
PL Developments, a leading supplier of over-the-counter, FDA-approved products in the analgesic, gastrointestinal, cough/cold, sleep/motion, and eye care categories, is an integrated single source for oral dosage development and manufacturing of over-the-counter pharmaceutical and nutritional products. The company focuses on innovation and commitment to the well-being of its customers, consumers, employees, and the community.

A few years ago, PL Developments realized that its IT systems could not adequately support the growth expectancy of the business. To get & stay ahead of the curve, it needed to implement an integrated application suite that would provide total visibility into every aspect of its business. The company implemented a full solution from Oracle including Oracle E-Business Suite Release 12.1.1 & Oracle's Agile PLM applications to improve its supply chain control, optimize inventory levels, streamline production scheduling, enhance customer service, & improve financial planning processes.
Highlights
 
Industry
Life Sciences
Employees
1000
 
Solution Footprint


Oracle E-Business Suite Release 12.1.1

Oracle Financials

Oracle Order Management

Oracle Discrete Manufacturing

Oracle Process Manufacturing

Oracle Advanced Supply Chain Planning
Oracle Production Scheduling

Oracle Warehouse Management

Oracle Quality

Oracle EDI Gateway

Oracle Human Resources

Agile Product Collaboration
Agile Product Cost Management

Demantra Demand Management

Oracle Business Intelligence

Enterprise Edition

Oracle User Productivity Kit

Oracle Business Accelerators

Business Challenges
Implement an integrated business application suite to enable the company to scale to support expected growth
Enhance supply chain control for private label, over-the-counter drug packaging solutions and tablets and capsules sold to retailers, supermarkets, and drugstores
Manage the end-to-end packaging process for customers, including artwork and label design, regulatory requirements support, call center activities, and distribution
Improve visibility into the production floor and streamline production schedules
 
Manage and plan inventory for customers to ensure proper levels are available and respond to orders within 24 to 72 hours
Perform supply and demand planning between its pharmaceutical manufacturing plant and bottling and packaging plant
 
KPIT's Implementation Methodology
PL Developments recognized the importance of positioning the implementation as a corporate project, not an IT project, to secure buy-in from critical business leads. It brought Oracle Partner KPIT on board in August 2009 to help examine the known requirements and deliverables for the project.
PL Developments and KPIT focused on training at every step of the way during the implementation so its business users could hit the ground running post go-live. PL Developments completed subsequent implementations in October 2010 (Hyperion) and November 2011 (Demantra) at this facility. It implemented Oracle Warehouse Management in its New York office in July 2010 and in its Miami facility in February 2012.
Solutions and Benefits
KPIT implemented Oracle E-Business Suite Release 12.1.1, Oracle's Agile Product Lifecycle Management, and Hyperion applications in just 10 months
 
Used Oracle Advanced Supply Chain Planning to improve inventory visibility identifying a capacity deficiency and the need to create a second shift to meet customer needs

 
Leveraged the visibility to match capacity to demand ceasing production on products in surplus and ramping up to produce a two- to three-week supply for other, more critically-needed products meeting stocking requirements within three months, post go-live
Optimized manufacturing scheduling to minimize the number of short runs while still ensuring that the company can ship products to its customers on demand
 
Utilized Oracle Warehouse Management and Oracle Advanced Supply Chain Planning to perform demand and supply planning between the pharmaceutical manufacturing plant (Miami, FL), and the bottling and packaging plant (Long Island, NY)
Provided visibility into a product's exact location at any time where it is shipped, and to which customer and kept an electronic record for easier regulatory compliance
Used Oracle E-Business Suite and Agile applications to manage product lifecycle processes and eliminate several hours of meetings each week by providing team members with the data visibility and control at the touch of a button
Streamlined budgeting process and forecasting accuracy with Oracle's Hyperion Advanced Forecasting and Demand Modeling, providing a layer for every department manager, including expenses and expenditure forecasts to help prepare for the upcoming year
 
Used Oracle Warehouse Management to eliminate the need to keep manual logs automating processes for managing bulk-product lot control, allocating bulk medications to specific product orders, and reducing errors across the board
 
Deployed Oracle User Productivity Kit to support training approximately 120 users on the new Oracle applications, enabling users to maintain productivity levels even immediately post go-live
Leveraged the new mixed-mode manufacturing feature in Oracle E-Business Suite Release 12.1.1 to implement Process Manufacturing in the Miami plant and Discrete Manufacturing in the Florida plant, in a single Oracle E-Business Suite instance
Used Oracle Business Accelerators to go-live with Oracle E-Business Suite in an aggressive timeline of just 10 months
 
"Since implementing Oracle E-Business Suite Release 12.1.1 and other supporting Oracle solutions, we have grown by 35% to 40%, attributable in part to the visibility the technology provides us into every aspect of our business. We now make decisions quickly, based on real data. We're smarter, faster, and more efficient, and it shows."

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Tom Crowe
Chief Information Officer, PL Developments

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