Revolutionizing Manufacturing Efficiency: RheinBrücke's Epicor MRP Solution Reshapes Alshaya Group's Operations

Alshaya Group founded in 1890 is a multinational retail franchise operator headquartered in Kuwait. its one of the premier brand franchise operators globally, providing customers with an unmatched selection of beloved international brands. Their portfolio of outlets spans Europe, the Middle East and North Africa, encompassing thousands of stores, cafes, restaurants, and leisure destinations, along with an expanding online and digital presence. They have a retail presence across multiple verticals and are leaders in the food and beverage segment offering unsurpassed brand experiences. These span across flagship stores and upscale restaurants in prestigious malls to local coffee shops and drive-throughs. They also have a burgeoning online presence. Their central cloud kitchen operates with a wide array of more than 15 brands within its scope. To handle the significant influx of food orders it receives, the kitchen used to rely on manual procedures and simplistic data management techniques. While these methods were functional, they posed challenges in effectively managing the extensive volume of orders across the diverse range of brands.

Reasons to change to a better solution

• More dependence on manual processes and labor
• Dependence on MS Excel for production planning, resulting in inefficiencies, errors, and extended man-hours.
• Inaccurate inventory information, and prolonged waiting times, lead to overproduction
• Fragmented Systems for Data Management

Our Solution

Epicor ERP seamlessly integrates with essential components of the manufacturing process, encompassing Production and Recipe Management, Inventory and Logistics Management, Quality Assurance, and the Quote to Cash modules, as well as with external systems like Oracle Financials, Algonomy (internal BI tool), AIMS (inhouse inventory management tool), and GOLD (another ERP solution used by management team) to enhance organizational efficiency. This integrated solution creates a unified platform for efficient data management. The system automates distribution processes for both batch and semi-continuous manufacturing, ensuring streamlined operations. Epicor MRP module enhances efficiency by providing precise recommendations for Purchase Orders and Jobs. Furthermore, the solution implements robust quality control measures at various stages, upholding stringent standards. Integration with the existing Source Systems ensures a cohesive flow of data. The deployment includes 13 Epicor reports designed to offer accurate and reliable insights into the manufacturing processes. To facilitate a smooth transition, change management strategies were implemented, complemented by regular adoption monitoring to ensure ongoing effectiveness.

Business Impact

Epicor allows for the automatic upload of data from each outlet in a specified format, significantly reducing the data upload time from over 32 man-hours to just over one hour, regardless of whether it involves 1- or 45-line items from a single outlet. This automation applies to data from over 1200 outlets, significantly expediting the data upload process. Within a short span of implementing document management using Epicor DocStar (IDC) and Epicor Kinetic Automation for uploads, over 280,000 orders were processed, requiring only 3 full-time equivalents (FTE), resulting in a huge reduction in data processing costs. This auto-upload reduced manual data entry, thereby minimising human errors. This streamlined approach accelerated order processing, ensuring prompt and accurate customer fulfillment.

By leveraging MRP, analysis of the demand for raw materials and finished goods is streamlined, enabling proactive planning and preventing both shortages and excess inventory to cater to 1200+ stores across the country. In addition to its role in demand-supply planning, the MRP functionality has proven instrumental in conducting thorough lot expiry checks. It systemically monitors expiration dates, ensuring that the inventory is regularly assessed to identify and mitigate the risk of dealing with outdated or expired batches.

Automation has not only expedited the movement of products but has also contributed to a marked decrease in transportaion costs. By streamlining the logistics and optimizing routes through automated algorithms, greater cost-effectiveness in transportation operations has been achieved. This strategic enhancement has minimized expenses and heightened the overall efficiency of the distribution network. The commitment to elevated quality extends to the finished products, where strict inspections and testing procedures are applied to ensure the result aligns with predetermined quality benchmarks. This dedication to excellence is not confined to the manufacturing floor; it extends to the inventory management practices, where meticulous controls are in place to maintain the integrity and quality of stored goods.

The efficient management of product shelf life and the optimization of shipment planning resulted in streamlined and effective supply chain operatons. The implementation of systems that enabled the prediction of production costs and processes allowed for the anticipation of challenges, the allocation of resources effectively, and the optimization of production workflows. The effective management of movement, release, and lot status for FEFO orders has been a key focus in optimizing inventory management. This systematic approach to inventory management contributed to cost savings, reduced waste, and enhanced customer satisfaction, aligning with the commitment to operational efficiency and customer-centric practices.