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Chapter -01
Managing Chain
introducing
SCM
mks mks@mdi.ac.in
http://www.mks507.vistapane l.net
Part
Teaser
3/23/13
1. 2. 3. 4.
2009
Apple Procter & Gamble Cisco Systems Wal-Mart Stores Dell PepsiCo Samsung Electronics IBM Research In Motion Amazon.com McDonalds Microsoft The Coca-Cola Company Johnson & Johnson Hewlett-Packard Nike Colgate-Palmolive Intel Nokia Tesco
Quantit y?
Sp ee ? d
V ar y? iet
Delivery Reliability
ity
Place
The right
Product
The right
Quantity
The right
Time
The right
Price
The right
Store
The right
Customer
Higher
Profits
Forecast ing
Locati on
Desig n Qualit y
Deliv ery
Reac h
Cost
Fit
Logistics/Supply Chain:
Part
Understand it
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Todays Challenges
To achieve economies of scale and scope Costs are significant To improve business focus and expertise Customer Expectations are increasing Supply and Distribution Lines are lengthening with complexity Adds Significant Customer value Customers Increasingly Want Quick & Customised Response
entitiesactivitiesproblem spots linkages? Connected by transportation and storage activities, and Integrated through information, planning, and integration activities
Raw materials manufacturers Intermediate products manufacturers End product manufacturers Wholesalers and distributors and Retailers
To
n
n
SCM covers the flow of goods from supplier through manufacturing and distribution channels to end user.
Jones and Riley (1987)
SCM techniques deal with the planning and control of total materials flow from suppliers to through end users.
Christopher (1992)
SCM is the management of a network of organizations that are involved, through upstream and downstream linkages, in the different processes and activities that produce value in the form of products and services in the hands of the ultimate customer.
Ayers (2000)
SCM is the design, maintenance and operation of supply chain processes for satisfaction of end users.
Sunil Chopra and Peter Meindl (2001)
SCM involves the management of flows between and among stages in a supply chain to maximize total profitability.
Vehicle Repair
Raw material Supplier Component Supplier Vehicle Manufacturer Spares Distributor Service Centre [Retailer] Customer
Pest Control
Customer
Electricity
Water [Nature]
Generating Station [Producer]
Fuel Supplier
Oil Compa ny
Upstream
Farm er
Focal Company
Internal
Downstream
Flour Cereal Grocery Reta Consu customer / consumer / client Proces Manufact Distribu il mer sor urer tor Groc manage relationship with whom.in which er order? CRM??? Supply Chain: Manufacturing Example Fore st Lumb er Provi der Corrugate d Manufact urer Products and Services Cash Information Deman dSuppl y
CUSTOMER CONSUMER
CRM??? CLIENT understand context and hence the relative preference accordingly.
Alternative 2)
Monitor the procedures of Company A and Company B for integrating and managing Link 2.
When to monitor when to let them own.. When Link to dictate? Company 2
B
Alternative 3)
Not involved, leave the integration and management up to Company A and Company B.
Imm. Suppliers
The Firm
Imm. Customer
Supply Chain
The Firm
The Firm
Upstream, where sourcing or procurement from external suppliers occur Internal, where packaging, assembly, or manufacturing take place Downstream, where distribution or dispersal take place, frequently by external distributors.
in which industry, which segment to be focused more? movement of information and money and the procedures supporting the
movement of a product or a service.
Materials flows are all physical products, new materials, and supplies that flow along the speed?... chain. flow quantum?... precedence? Information flows relates to all data associated with demand, shipments, orders, returns and schedules. Financial flows include all transfers of money, payments, credit card information, payment schedules, e-payments and credit-related data.
UPSTREAM
INTERAL
DOWNSTREAM
Supply Chain
Value Chain
Demand Chain
Most companies are working to create seamless processes within their own four walls. (47%) Many companies house SCM in purchasing & focus on integration with Key Suppliers first-tier suppliers (34%)
The Firm
Purchasing Production Marketing R&D Logistics
Common
The Firm
but
Some companies house SCM in The Firm Key Customer marketing & focus on rare makes a difference. integration key customers. (11%) needs a delicate balance among with sensitive
relations?
The Firm Key Customer
Suppliers
Key Suppliers
Customer
Rare
Collaboration from suppliers' supplier to customers' customer is a vision not yet fully realized!!!
N 20 80 Y
From the customers perspective 8% satisfaction From the operations perspective 90% satisfaction N 40 N Y 1 10 Y 9 N 10 Y N
Customer satisfaction 8
N 10 70 Y N 50 Y 20 Customer orders?
N 1 8 Y
Taking a customer perspective of supply performance can lead to very different conclusions
Received as promised?
INPUT
Value Added Process
Supplier Performance =
Actual Inputs Expected Inputs Input Used Input Available Actual Outputs Inputs Used Actual Outputs Planned Outputs Actual Inputs Expected Inputs
EFFICIENCY
Utilization =
OUTPUT
Productivity =
OUTCOME
Performance =
IMPACT
Customer Satisfaction =
First Revolution:
Second Revolution: (Toyota Motor Co. 19601970) always existed a leader there Wide Variety to make footprint on sand of supply chain Long-term relationship with suppliers landscape ? Third Revolution: (Dell Computers 1995Current)
Customized products Medium-term relationship with suppliers Suppliers have to maintain technology and cost leadership
1. 2. 3. 4. 5. 6.
7.
learn what constitutes in total known as Product Design and New Product supply chain management ?
Introduction Service and After Sales Support Reverse Logistics and Green Issues Outsourcing and Strategic Alliances Metrics and Incentives Global Issues.
Location Transportation and Logistics Inventory and Forecasting Marketing and Channel Restructuring Sourcing and Supplier Management Information and Electronic Mediated Environments
Cycle view: processes in a supply chain are divided into a series of cycles, each performed at the interfaces between two successive supply chain stages Push/pull view: processes in a supply chain are divided into two categories depending on whether they are executed n in response to a customer order (pull) n in anticipation of a customer order (push)
basis of viewswhyhow
Each cycle occurs at the Custo interface between two successive stages mer Customer Order Cycle n Customer order cycle (customer-retailer) Reta n Replenishment cycle Replenishment Cycle iler (retailer-distributor) n Manufacturing cycle be synchronized them. Distrib can they (distributorquanitywisetimewise.anticipationwise? utor Manufacturing manufacturer) Cycle n Procurement cycle Manufact (manufacturerurer Procurement Cycle supplier)
size of order predictability of orders
Supp Cycle view clearly defines processes involved and the owners of each lier process.
Specifies the roles and responsibilities of each member and the desired
In Pull systems, work release is based on actual demand will you push the rope or pull it? or the actual status of depends the downstream customers
May cause long delivery lead times Acts reactively Making a specific resume for a company after talking to the recruiter
PUSH PROCESSES
Push/Pul l Boundar y
Custo mer
Order Arrives
PULL PROCESSES
Supply chain processes discussed in the two views can be classified into
n n n
Supplier Relationship Management (SRM) Internal Supply Chain Management (ISCM) Customer Relationship Management (CRM)
Integration among the above three macro processes is critical for effective and successful supply chain management
Part
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Value-Added Roles of Logistics The five principal types of economic utility which add value to a product or service : Form Time Place Quantity Possession
what?
where? when?
why?
How much?
While form and possession utility are not specifically related to logistics, neither would be possible without getting the right items needed for consumption or production to the right place at the right time and in the right condition at the right cost. These "five rights of logistics," credited to E. Grosvenor Plowman, are the essence of the two utilities provided by logistics: time and place utility.
Logistics in the Firm: Factors Affecting the Cost and Importance of Logistics
Competitive Relationships n Inventory / order cycle length. n Inventory / lost sales effect n Transportation / lost sales effect Product Relationships n Product dollar value / logistics costs. n Weight density / logistics costs. n Susceptibility to loss & damage / logistics costs. Spatial Relationships
1
Inventory level
Spatial Relationships:
Spatial Relationships are extremely significant to logistics is spatial relationships, the location of fixed points in the logistics system with respect to demand and supply points. Spatial relationships are very important to transportation costs, since these costs tend to increase with distance.
Part
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On the basis of decoupling point (ETO, MTO, ATO, MTS) supply chain Push vs. Pull supply chain Lean vs. Agile supply chain Efficient vs. Responsive supply chain
deliver product to
The time for which a customer is willing to wait to have their demand fulfilled Short D-times face increased supply chain challenges compared with those who have long D-times.
Control Simplify
Optimizing throughput and improving process capability Untangling process flows and reducing product complexity straightening process flows and reducing batch sizes Improving communications and implementing teams Adding customer-specific parts as late as possible Using robots and IT systems
Compres s Integrate
Coordina te Automat
Assemble WIP
Customer Decoupling Point
ETO
MTO
Schedule Orders
ATO
Schedule Modules
MTS
Schedule Finished Goods
Long
Short
Fab
Push-Pull Strategy
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Furniture SC
Grocery SC
Traditional PC Industry
PC SUPPLY CHAINS
Customer Customer Virtual Integration
PUL L PUS H
Suppliers
Dell
PUL L PUS H
MTS
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Supply chain dynamics Supply chains with different end objectives need to be managed in different ways
Match product characteristics with supply chain characteristics
Efficient supply chains are designed for efficiency and low cost by minimizing inventory and maximizing efficiencies in process flow. (Lean) Responsive supply chains focus on flexibility and responsive service and are able to react quickly to changing market demand and requirements. (Agile)
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Functional products
Predictable Few changes Low variety Price stable Long lead-times Low margin
Nature of demand
Innovative products
Unpredictable Many changes High variety Price markdowns Short lead-times High margin
Supply chain Respon Efficie objectives Low throughput times Low cost sive nt
Minimum inventory
Low-cost suppliers
High utilization
Deployed inventory
Flexible suppliers
High utilization
New models of existing goods: Entirely new product: e.g. fashion item e.g. new TV set
Highly efficient
Textile mill
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Product Characteristics
C am pbell's Soup L ife cycle C ontribution m argin V ariety Forecast error Stock -out rate Forced m arkdow ns M ake -to-order L T
Fashion
A pparel
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1969
1979
1989
1999
2009
3/23/13
Fall
Winter
Spring
3/23/13
Margins?
<
Retail Price: $1.39 Retail Price: $139.50
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<
Unchanged over years, only 5% Differed in color, size, style, etc., 95% new
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Forecasting Error?
<
Highly predictable, service level of 98% High forecast error, 40-100% error
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Stockout Rate?
<
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Markdowns?
<
Rare Deep discount in the end of the season
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Efficient vs Responsive
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Factor
Operation strategy
Make-to-stock or standardized Make-to-order, or customized service or services or products; emphasize high products; emphasize variety volumes Low High If needed to enable fast delivery time Shorten aggressively Emphasize fast delivery time, customization, variety, volume flexibility, top quality
Capacity cushion
Inventory investment Low; enable high inventory turns Lead time Shorten, but do not increase costs
Supplier selection
Lean vs Agile
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Distinguishing attributes Typical products Marketplace demand Product variety Product life cycle Customer drivers Profit margin Dominant costs Stockout penalties Purchasing policy Information enrichment Forecasting mechanism 3/23/13
Lean supply Commodities Predictable Low Long Cost Low Physical costs Long-term contractual Buy materials Highly desirable Algorithmic
Agile supply Fashion goods Volatile High Short Availability High Marketability costs Immediate and volatile Assign capacity Obligatory Consultative
Characteristic Logistics focus Partnerships Key measures Process focus Logistics planning Volumes Key drivers
Lean Eliminate waste Long-term, stable Output measures like productivity and cost
Agile Customers and markets Fluid clusters Measure capabilities, and focus on customer satisfaction
Work standardization, conformance Focus on operator self-management to to standards maximize autonomy Stable, fixed periods Predictable volumes and usage patterns Instantaneous response Unpredictable volumes and usage patterns
Economies of scale - high volumes, Ability to deliver - short and reliable lead low cost Consolidation of global times volumes Ability to respond at short notice Low - generic items High - customized items Close to the integration centre - search for responsiveness
Customisation
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Part
3/23/13
Understand the Capabilities of your SC Match the Wishes with the Capabilities
Range of demand, pizza hut stable Production lot size, seasonal products Response time, organ transplantation Service level, product availability Product variety Innovation Accommodating poor quality
Late: predictable demand, lower margins, price is important Product life cycle
Shift from responsiveness to efficiency
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Responsivene ss
Ef Fr ficie on n tie cy r
WAL-MART
Lo w Hig h
Cost
(Efficiency)
Lo w
INTRODUCTION
High Cost
Responsiveness spectrum
of it e F n Zo egic at r t S
MATURING COMMODITY
Certain demand
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Responsiveness
Facilities
Inventory
Sourcing
Pricing
Information exchange is necessary for the most extensive modes of coordination sought in contemporary supply chains. It allows the supply chain to improve simultaneously its efficiency and responsiveness. Information-related decisions
Push vs. pull Extent and modes of information sharing and coordination Forecasting and Aggregate Planning schemes Pricing and revenue management policies Enabling Technologies:
Electronic Data Interchange (EDI): Enables paperless transactions, primarily for backend operations of the SC. The Internet and the WWW. Enterprise Resource Planning (ERP): enables transactional tracking and global visibility of information in the SC. Supply Chain Management (SCM) software: decision support tools.
Facilities places where inventory is stored, assembled, or fabricated production sites and storage sites Inventory raw materials, WIP, finished goods within a supply chain inventory policies Transportation moving inventory from point to point in a supply chain combinations of transportation modes and routes Information data and analysis regarding inventory, transportation, facilities throughout the supply chain potentially the biggest driver of supply chain performance Sourcing functions a firm performs and functions that are outsourced Pricing Price associated with goods and services provided by a firm to the supply chain
Facilities
Location
centralization (efficiency) vs. decentralization (responsiveness) other factors to consider (e.g., proximity to customers)
economies of scale (efficiency priority) larger number of smaller facilities (responsiveness priority)
Capacity (flexibility versus efficiency) Manufacturing methodology (product focused versus process focused) Warehousing methodology (SKU storage, job lot storage, cross-docking)
Inventory
Unexpected changes in customer demand (always hard to predict, and uncertainty is growing)
Types of Inventory
Cycle inventory
Average amount of inventory used to satisfy demand between shipments Depends on lot size inventory held in case demand exceeds expectations costs of carrying too much inventory versus cost of losing sales inventory built up to counter predictable variability in demand cost of carrying additional inventory versus cost of flexible production Takes advantage of bargains.
Safety inventory
Seasonal inventory
Uncertain supply
Quantity Quality Costs Delivery time
Opportunistic Inventory:
Inventory exists because of a mismatch between supply and demand Source of cost and influence on responsiveness If you move your inventory faster, you dont need as much inventory (inventory velocity) If responsiveness is a strategic competitive priority, a firm can locate larger amounts of inventory closer to customers If cost is more important, inventory can be reduced to make the firm more efficient Trade-off: More inventory increases responsiveness, less inventory increases efficiency (reduces cost).
Shortage
Excess
Transportation
Moves the product between stages in the supply chain Impact on responsiveness and efficiency Faster transportation allows greater responsiveness but lower efficiency Also affects inventory and facilities
If responsiveness is a strategic competitive priority, then faster transportation modes can provide greater responsiveness to customers who are willing to pay for it Can also use slower transportation modes for customers whose priority is price (cost)
Mode(s) of Transportation
Air: fastest but most expensive Truck: Relatively quick, inexpensive and very flexible mode Rail: Inexpensive mode to be used for large quantities Ship: Slowest but often the most economical Pipeline: Used (primarily) for oil and gas Electronic transportation: for goods as music and movies
route: path along which a product is shipped network: collection of locations and routes
Transportation Networks
Information
Push (MRP) versus pull (demand information transmitted quickly throughout the supply chain) Coordination and information sharing Forecasting and aggregate planning Extent and modes of information sharing and coordination Pricing and revenue management policies Enabling technologies EDI Internet ERP systems Supply Chain Management software
The connection between the various stages in the supply chain allows coordination between stages Crucial to daily operation of each stage in a supply chain: e.g., production scheduling, inventory levels Allows supply chain to become more efficient and more responsive at the same time (reduces the need for a trade-off)
Sourcing
Pricing
Set of business processes required to purchase goods and services in a supply chain Supplier selection, single vs. multiple suppliers, contract negotiation
Pricing strategies can be used to match demand and supply Firms can utilize optimal pricing strategies to improve efficiency and responsiveness Low price and low product availability; vary prices by response times Pricing and economies of scale Everyday low pricing versus highlow pricing Fixed price versus menu pricing
Responsiveness
Availability Speed Proximity / Flexibility High cost/streamlined/ reliable
Strategic Scope
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The functions and stages within a supply chain that devise an integrated strategy with a shared objective One extreme: each function at each stage develops its own strategy Other extreme: all functions in all stages devise a strategy jointly
Five categories:
n n n n n
Intracompany intraoperation scope Intracompany intrafunctional scope Intracompany interfunctional scope Intercompany interfunctional scope Flexible interfunctional scope