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Alessandro Piatti
Supply Chain Strategy Deployment
Whirlpool Europe
Cassinetta’ s meeting Dec 9 th 2008
•8.45 Welcome @ Cassinetta Gate entry process
•Business contest
•Business contest
-2-
1
Whirlpool
General introduction
WHIRLPOOL CORPORATION
-4-
2
Brand Portfolio
We Touch All Key Consumer Segments
Cooking passionates
Premium segment
Quality minded
Home enthusiast
Up market
Style and design minded
Time pressure
Fashion oriented
Technology / design driven
Mass market
Young families
Value sensitive
Passionate about simplicity
Looking for reassurance
-5-
g #4 position as manufacturer;
#1 as Whirlpool brand
27 . S.Africa.
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3
Supply Chain Process
Factories Customer
Order To Delivery
Suppliers Trade
-7-
MTS
Make To Stock
Forecast Order
VMI
Vendor management inventory
Forecast Stock re-fill
USS
Forecast Upstream Stock
Order
BTO
Forecast Built To Order
Order
4
Whirlpool Europe
Planning process
Monthly OPD
Monthly
MonthlyOPD
OPD
Monthly
MonthlyOPD
OPD
Monthly
MonthlyOPD
OPD Monthly
Monthly
Monthly OPD Monthlyvolume
volumecontrol
control&&factory
factoryload
load
MonthlyODP
ODP review
reviewM+1/m+3
M+1/m+3&&Year
YearGoods
GoodsMovement
Movement
review
review
review
reviewof
ofDemand
Demand
Monthly S&OP Monthly S&OP
&&load
loadVolume
Volume/ /
Monthly S&OP
Monthly S&OP extraordinary
extraordinary
Monthly S&OP
actions
actionsetc
etc
Weekly
WeeklyGross
Grossdemand
demandFCST
FCSTreview
reviewby
bySKU/Plant
SKU/Plant Weekly
WeeklyAvailability
Availabilitycheck
check
calls
calls
Daily
Dailyregenerated
regeneratedsupply
supplyplan
plan / /inventory
inventorynetted
netted&&last
lastminutes
minutesSales
Salesorders
ordersqualified
qualified
5
SHORT TERM – DAILY PLANNING PROCESS
Weekly Rolling: Forecast netting & net requirements calculation (full horizon)
Frozen Period
Lead time
SUPPLY PLAN
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SUPPLY PLAN
1. FACTORY CONSTRAINTS
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6
1. FACTORY CONSTRAINTS
FACTORY CAPACITY
QUALITY constraints
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During this period is not possible to change the production (exceptions will be managed) .
This is the reason for which we need a very HIGH level of Forecats Accuracy, in order:
-To Be able to satisfy the market requirements;
-For the factory to plan the correct purchase requisitions, in order to be alligned in terms of stock value
(inventory) and supply chain requests;
-To work with and for the FDC in order to minimize the stock level of finished goods ;
-To work with and for the FDC in order to schedule the shipments every week: DEPLOYMENT PLAN and
manual adjustment; this is related to the availability of means of transport !!
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7
Master plan - Demand propagation - Lead time effect
RDC
Amiens
RDC
Isled’abeau
RDC
Oosterhaut
Factory
Slush
Liquid
Whirlpool Europe
Network & footprint
8
Whirlpool Europe’s
delivery models
Production Sites
Headquarters Factory DCs’
Norrköping
M
TS
Regional DCs’ BBP’s
BTO / DD
Wroclaw
Poprad
Amiens Neunkirchen
Schorndorf Trade
Comerio Trento
Cassinetta
Siena
Naples
Isithebe Consumer
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Brand:
Prodotti:
Cooking (Cooktops – Ovens – Hoods – MWO)
Cooling
Washing
Dishwashing
Drying
Accessories
Small appliances (KA)
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9
Segmentazione canale Retail (Eldom)
INDIPENDENT
Realtà sempre meno presente.
Piccoli pdv che decidono di affiliarsi
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10
Segmentazione canale Kitchen
KITCHEN MANUFACTURER KITCHEN DISTRIBUTORS KITCHEN RETAILER
RIVENDITORI DI
MOBILI/CUCINE
CONSUMATORE FINALE
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• Interfaccia della forza vendita: • Pianificazione delle consegne ai clienti • Gestione della demand e del relativo
mediante negoziazione data di scarico supply
• Inseriscono ordini a sistema
• Gestione del metodo di consegna ai • Interfaccia con la Supply Chain
• Controllano correttezza delle
clienti Centrale
informazioni legate a promozioni
& sconti • Supervisione delle attività di • Gestione dello stock
magazzino e del trasporto
• Verificano disponibilità dei • Gestione e coordinamento BTO
prodotti allocandoli presso i • Gestione e relazione con i fornitori del
magazzini più vicini al cliente trasporto e della logistica
• Forniscono feedback & • Analisi e monitoraggio costi della
conferme alla forza vendita & Supply Chain
clienti
• Gestiscono resi & claim desk
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11
Flusso informazioni tra le funzioni DCI
Forza Vendita
Inserisce ordini a sistema
Order Desk
Concordano
SAP
promozioni con Trade Marketing Inseriscono, controllano e
NAM
verificano ordini in SAP,
creazione delivery ad hoc
Planning Logistica
Inseriscono DP in SAP della fsct Negoziazione Consegne,
per SKU/Plant/Wk, rescheduling e preparazione shipment
creazione massiva delivery gestione consegne
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Supply
FDC
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12
Processo di Spedizione Logistica Italia
Pianificazione del trasporto Picking Carico
Operatori di magazzino
Planner contatta via
caricano il mezzo
telefono, fax, mail la
Operatore di magazzino sulla rispettando l’ordine di
logistica del cliente per
base della picking list esegue carico impartito dal
negoziare data di ricezione
il prelievo dei prodotti planner del trasporto
disponendoli per mezzo e per
ordine di consegna sulla
marshalling area Operatori di magazzino
Planner: in base alle date
concordate,ai m³ di ogni caricano il mezzo
consegna determina il rispettando l’ordine di
numero mezzi di trasporto carico impartito dal
necessari Operatore addetto alla planner del trasporto
qualità controlla per ogni
prodotto lo stato qualitativo
le quantità e il codice
Planner: in base alle date Operatore Ufficio
concordate,ai m³ di ogni magazzino conferma la
consegna determina il numero spedizione delle delivery
mezzi di trasporto necessari e in SAP
metodo distributivo: DIR/BBP Operatore addetto alla
qualità controlla per ogni
prodotto lo stato
qualitativo, le quantità e il
codice Creazione automatica in
Planner: crea in SAP la SAP della fattura e della
shipment (viaggio) per valorizzazione del
ogni mezzo di trasporto trasporto
-25-
Whirlpool Europe
Quality @ warehouses
13
Quality in Supply Chain Strategy
Strategy
Supply Chain Objectives
Mission:
“To support our Brand Value Creation Strategy Serveeach
Serve eac hcustomer
customer
we will deliver ‘thewa
‘the wayyhe
hewould
wouldlike
liketo
to be
beserved’
served’
atbest-in-class
at best-in-c lass
sustainable competitive advantage” workingcapital
ca pitaland
andcosts
c ostslevels
levels
working
Enablers:
Customer Quality
Competitive Benchmarking Service
Service
Extended Supply Chain Assignments Excellence
Exc ellence
Supply Ch ain Business Model Inventory
Inve ntory Costt
Cos
Distribution Network
Supply Ch ain Processes
Supply Ch ain Execu tion - Marke t, S CM, Direct
Lean
CC OpEx
Org anizatio n & Pe ople
VISION:
VISION: Installing
Installing an
an uncompromising
uncompromising approach
approach to
to Quality
Quality in
in our
our logistics
logistics operations,
operations,
while
while reducing
reducing by
by 50%
50% products
products handling
handling and
Update March 2 007 and transport
transport damages
damages -14-
-27-
Capability:
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14
Process to build a robust Platform Capability
• Identification/Definition
• Measurement
Our
Our goal
goal is
is to
to reduce
reduce Non-Quality
Non-Quality costs
costs
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• Identification/Definition
• Measurement
Our
Our goal
goal is
is to
to reduce
reduce Non-Quality
Non-Quality costs
costs
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15
Identification: How do we proceed
Workshop Capability
Results
Manag. Commitment
Organisation
WPL Metrics Processes & Procedures
FACTORY
Logistics
P.C. Proposal
Packaging Equipment Skills
Iso9001:2000
Existing
External
Experience
-31-
Capabilities Elements
CAPABILITY ELEMENTS
Logistic Organisation for Quality
Quality Culture Promotion
ORGANISATION & LEADERSHIP Quality System Definition & Implementation
Management Review
Safety Environment Management
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16
Platform Capabilities: Evaluation
• Identification
• Measurement
Our
Our goal
goal is
is to
to reduce
reduce Non-Quality
Non-Quality costs
costs
-33-
5: Unobtainable
4: World Class/Best in Class
no visible quality issue that can be related to capability
no one can teach us how to do better
3: Very Good
as good as anybody else
consistent, very high level of quality
2: Average
1: Poor
0: Capability does not exist in function
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17
Platform Capabilities: Spider-charts
Element Capability
• Identification/Definition
• Measurement
Our
Our goal
goal is
is to
to reduce
reduce Non-Quality
Non-Quality costs
costs
-36-
18