Method for identifying product assets in a supply chain used to satisfy multiple customer demands

A method for identifying product assets in a supply chain used to satisfy customer demands, comprising:

• (a) selecting, by a processor of a computer system, all records from said requisition map file of components and products having low-level codes equal to a current low-level-code from a bill of material listing all components required for products, each component and product having a low-level-code indicating a sequence in which said components are assembled into said products and each product and component having a unique part-number;
• after (a), (b) mapping, by said processor of said computer system, a planned inventory requisition file comprising component availability schedules and a customer demand file comprising product shipment schedules for said products assembled from said components into a requisition map file associating said component availability schedules and said product shipment schedules and including quantities of each component to be used for each product;
• after (b), (c) selecting, by said processor of said computer system, from a planned asset file comprising component schedules, records having part numbers equal to the part numbers of records selected in (a);
• after (c), (d) selecting, by said processor of said computer system, from said planned inventory requisition file, records having part numbers equal to the part numbers in the records selected in (a);
• after (d), (e) mapping, by said processor of said computer system, records selected in steps (c) and (d) into a coverage file associating component availability with component requirements for each product;
• after (d), (f) mapping, by said processor of said computer system, said coverage file and records of corresponding part numbers from said requisition map file into a demand pegging output file comprising demand pegging output records, said demand pegging records associating a quantity and an availability date of each component required to produce a required quantity of each of said products, each demand pegging record consistent with a feasible schedule;
• after (f), (g) generating, by said processor of said computer system, additional records in said requisition map file for components required to fabricate products whose records were mapped into said demand pegging output file in (f);
• and
• after (g), (h) incrementing, by said processor of said computer system, the current low-level-code and repeating steps (b) through (h) until the current low-level code is higher than a highest low-level-code of any said component or said product.

A computer system comprising a processor, an address/data bus coupled to said processor, and a computer-readable memory unit adapted to be coupled to said processor, said memory unit containing instructions that when executed by said processor implement a method for identifying product assets in a supply chain used to satisfy customer demands, said method comprising the computer implemented steps of:

• (a) receiving a customer demand schedule for delivery of products;
• (b) receiving a planned inventory requisition schedule of all components to be assembled into said products, said planned inventory requisition schedule generated from said customer demand schedule by a production scheduling run;
• (c) receiving customer bills of materials listing all components required for each of said products;
• after (a), (b) and (c), (d) generating first and second coverage files from said planned inventory schedule, from said customer demand schedule and from said bills of materials, said first coverage file containing a list of assets including products to be used for product shipments and components to assembled into products to meet product shipment demands, said second coverage file containing a list of all other assets;
• and
• after (d), (e) generating from said first and second coverage files, a set of demand pegging records, said demand pegging records associating a quantity and an availability date of each component of each product with a required quantity of each of said products, each demand pegging record consistent with said planned inventory requisition schedule.

A computer system comprising a processor, an address/data bus coupled to said processor, and a computer-readable memory unit adapted to be coupled to said processor, said memory unit containing instructions that when executed by said processor implement a method for identifying product assets in a supply chain used to satisfy customer demands, said method comprising the computer implemented steps of:

• (a) selecting all records from said requisition map file of components and products having low-level codes equal to a current low-level-code from a bill of material listing all components required for products, each component and product having a low-level-code indicating a sequence in which said components are assembled into said products and each product and component having a unique part-number;
• after (a), (b) mapping a planned inventory requisition file comprising component availability schedules and a customer demand file comprising product shipment schedules for said products assembled from said components into a requisition map file associating said component availability schedules and said product shipment schedules and including quantities of each component to be used for each product;
• after (b), (c) selecting, from a planned asset file comprising component schedules, records having part numbers equal to the part numbers of records selected in (a);
• after (c), (d) selecting, from said planned inventory requisition file, records having part numbers equal to the part numbers in the records selected in (a);
• after (d), (e) mapping records selected in steps (c) and (d) into a coverage file associating component availability with component requirements for each product;
• after (d), (f) mapping said coverage file and records of corresponding part numbers from said requisition map file into a demand pegging output file comprising demand pegging output records, said demand pegging records associating a quantity and an availability date of each component required to produce a required quantity of each of said products, each demand pegging record consistent with a feasible schedule;
• after (f), (g) generating additional records in said requisition map file for components required to fabricate products whose records were mapped into said demand pegging output file in (f);
• and
• after (g), (h) incrementing the current low-level-code and repeating steps (b) through (h) until the current low-level code is higher than a highest low-level-code of any said component or said product.

A program storage device readable by machine, tangibly embodying a program of instructions executable by the machine to perform method steps for identifying product assets in a supply chain used to satisfy customer demands said method steps comprising:

• (a) receiving a customer demand schedule for delivery of products;
• (b) receiving a planned inventory requisition schedule of all components to be assembled into said products, said planned inventory requisition schedule generated from said customer demand schedule by a production scheduling run;
• (c) receiving bills of materials listing all components required for each of said products, each component and product having a low-level-code indicating a sequence in which said components are assembled into said products and each product and component having a unique part-number;
• after (a), (b) and (c), (d) generating first and second coverage files from said planned inventory schedule, from said customer demand schedule and from said bills of materials, said first coverage file containing a list of assets including products to be used for product shipments and components to be assembled into products to meet product shipment demands, said second coverage file containing a list of all other assets;
• and
• after (d), (e) generating from said first and second coverage files, a set of demand pegging records, said demand pegging records associating a quantity and an availability date of each component of each product with a required quantity of each of said products, each demand pegging record consistent with said planned inventory requisition schedule.

A program storage device readable by machine, tangibly embodying a program of instructions executable by the machine to perform method steps for identifying product assets in a supply chain used to satisfy customer demands said method steps comprising:

• (a) selecting all records from said requisition map file of components and products having low-level codes equal to a current low-level-code from a bill of material listing all components required for products, each component and product having a low-level-code indicating a sequence in which said components are assembled into said products and each product and component having a unique part-number;
• (a), (b) mapping a planned inventory requisition file comprising component availability schedules and a customer demand file comprising product shipment schedules for said products assembled from said components into a requisition map file associating said component availability schedules and said product shipment schedules and including quantities of each component to be used for each product;
• after (b), (c) selecting, from a planned asset file comprising component schedules, records having part numbers equal to the part numbers of records selected in (a);
• after (c), (d) selecting, from said planned inventory requisition file, records having part numbers equal to the part numbers in the records selected in (a);
• after (d), (e) mapping records selected in steps (c) and (d) into a coverage file associating component availability with component requirements for each product;
• after (d), (f) mapping said coverage file and records of corresponding part numbers from said requisition map file into a demand pegging output file comprising demand pegging output records, said demand pegging records associating a quantity and an availability date of each component required to produce a required quantity of each of said products, each demand pegging record consistent with a feasible schedule;
• after (f), (g) generating additional records in said requisition map file for components required to fabricate products whose records were mapped into said demand pegging output file in (f);
• and
• after (g), (h) incrementing the current low-level-code and repeating steps (b) through (h) until the current low-level code is higher than a highest low-level-code of any said component or said product.