Scm_v20 -- PPT - Presentation -- 170 Pages

8/2/2019 Scm_v20 -- PPT - Presentation -- 170 Pages

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Supply Chain

Management Guide © Imants



The Supply Chain Management Guide

1. Introduction



1. Introduction 1.1. Key Concepts1.1.1. Supply Chain

The Supply Chain is:• the sequence of suppliers that contribute to the

creation and delivery of a good or service to endcustomers.



1. Introduction 1.1. Key Concepts1.1.2. Logistics

Logistics is:• the management of the storage and flow of goods,

services and information throughout yourorganisation.



1. Introduction 1.1. Key Concepts1.1.3. Supply Chain Management

Supply Chain Management is:• organizing the cost effective flow and storage of

materials, in-process inventory, finished goodsand related information from point of origin to

point of consumption to satisfy customerrequirements.



A Business Philosophy

A way of doing business with your

customers and suppliers.

1. Introduction 1.1. Key Concepts1.1.4. A Philosophy



1.2 Principal Issues1.2.1. Supply Chain (1)

Supply Chain

The supply chain of a company consists of differentdepartments, ranging from procurement ofmaterials to customer service.

The supply chain includes activities associated withinventory (materials) acquisition, storing, use inproduction, transit, and delivery to customers.

1. Introduction



1.2 Principal Issues1.2.1. Supply Chain (2)

The activities are planned, executed, and monitoredunder the guidelines set by the company’s chosen

customer service levels and in line with thecompany’s other operating goals.

1. Introduction



1. Introduction 1.2. Principal Issues1.2.2. Elements of Logistics

Elements of Logistics:• materials management:

• sourcing and receiving of raw materials or unfinishedproducts for subsequent use

• material flow system:• the ability to locate and schedule material through to end

production and disposition

• physical distribution:

• the delivery of finished goods to customers



1.2. Principal Issues1.2.3. Logistic Goal

1. Introduction

Logistic goal and objectives

The rightproducts

The rightquantity

The rightmoment

At minimalcost

Flexibility Delivery

reliability

Delivery time/

lead time

Inventory

level



1.2. Principal Issues1.2.4. Logistic Steps

Logistic steps:• accepting a customer order

• receive and enter

• credit clearance / authorize

• delivery commitment• supplier ordering

• forecasting demand

• scheduling manufacturing

• inventory management

• delivery to customer.

1. Introduction



1.2. Principal Issues1.2.5. Evolution

1. Introduction

Quality products

Lowest possible cost

Order fulfillment

Integration of supply chainsCustomer service

Preferred partnersCommunication

Supply chain communitiesCommon goals, objectives

Supply

Chain

Evolution



1. Introduction 1.2. Principal Issues1.2.6. The Goal

Supply Chain Management Goal

To evolve a company’s supply chain into an optimallyefficient, customer-satisfying process, where the

effectiveness of the whole supply chain is more importantthan the effectiveness of each individual department.



1. Introduction 1.2. Principal Issues1.2.7. Focus

Supply Chain Management focuses on businessprocesses:

• product design

• planning

• order management• stock management

instead of functions:

• sales

• purchasing

• production



1. Introduction 1.2. Principal Issues1.2.8. Drivers of Change (1)

Drivers of change:• outsourcing trend

• actual customer demand: speed, flexibility andcompetitive pricing

• new software: ERP, sophisticated applicationsoftware



1. Introduction 1.2. Principal Issues1.2.8. Drivers of Change (2)

• new technologies• Electronic Data Interchange (EDI)

• internet, intranet, extranet

• wireless communications

• teleconferencing and telecommuting

• bar coding.



1.2. Principal Issues1.2.9. Activities

Supply chain management activities:• Forecasting demand

• Selecting suppliers

• Ordering material

• Managing inventory

• Scheduling production

• Shipping and delivery

• Organizing information exchange

1. Introduction



1.3. Analysis1.3.1. Diagram

1. Introduction

Understand thecustomer

Understand theproduct

Understand theprocess

Understand theinformation flow



1. Introduction 1.3. Analysis1.3.2. Understand the Customer (1)

Know and understand the customers:• Your existing customers, i.e.,

• demographics

• existing and potential number

• income levels?• Who are your potential customers?

• How might these customers be grouped?

• For which percentage of sales is each group

responsible?



1. Introduction 1.3. Analysis1.3.2. Understand the Customer (2)

• What is the effect of various methods ofcommunications (i.e., telephone, fax, e-mail,internet telephoney systems) in your relation withyour customers?

• What do your customers want from you?

• How well do your competitors meet customersneeds?



1. Introduction 1.3. Analysis1.3.3. Understand the Products

Understand the products:• How many?

• Where are they?

• Which percentage of sales?

• What is the product life cycle?

• What is the product mix?



1. Introduction 1.3. Analysis1.3.4. Understand the Process

Understand the production process:• process flow

• linear flow

• job shop - batch flow

• assembly line• continuous flow

• project flow

• order fulfillment strategy

• make-to-order

• make-to-stock.



1. Introduction 1.3. Analysis1.3.5. Understand the Information Flow

Understand the information flow:• What information is required for effective

decision-making at each stage in the supplychain?

• What data has to flow between each part of thesupply chain?



1. Introduction 1.4. Performance Indicators (1)

A total view must be taken in assessing

performance.

Performance measurements need to be focusedon what factors add to total performance, total

value or total cost.

The principle performance indicator is customerservice. Optimum service levels are necessary

from each supplier to each customer throughoutthe supply chain.



1.4. Performance Indicators (2)1. Introduction

Suppliers Inputs Addingvalue

Outputs Customers Results

EffectivenessEfficiency

Productivity

Profitability

Customer Service + Quality

CustomerService




Effectiveness:• accomplishment of the right things, on time,

within the requirements specified.

Efficiency:

• resources expected to be consumed divided byresources actually consumed.




Productivity:• measures of output divided by measures of input

for a given period of time.

Profitability:

• relationship between revenues and costs.




2. Purchasing and Procurement



2. Procurement 2.1. Key Concepts

Purchasing: implies the monetary transaction.

Procurement: the responsibility for acquiring thegoods and services the organization needs:

• goods:

• raw materials• production parts

• maintenance, repair and operating supplies (MRO)

• services:

• consulting services• utilities

• workers health care benefits.



2. Procurement 2.2. Principal Issues2.2.1. Evolution in Purchasing

Evolution in Strategies for Purchasing

Focus on price Focus on quality,

reliability,responsiveness,

and total cost Strategic focus

- supplier relationships- forecasting- cycle time



2. Procurement 2.2. Principal Issues2.2.2. The Procurement Process (1)

The Procurement Process:

• preparation:

• identify needs, such as dependability, long termavailability

• evaluate user requirements to ensure suitability of

purchase• forecast when and how purchase will be needed

• identify and select suppliers

• develop an efficient ordering system for control

• negotiation:• bidding processes

• contracts



2. Procurement 2.2. Principal Issues2.2.2. The Procurement Process (2)

• order placing via appropriate channels (i.e.authorized purchase order)

• receiving including adjustments for damages,short or over-shipping and incorrect costs

• monitoring supplier performance.



2.2. Principal Issues2.2.3. Supply Uncertainty

Elements of supply uncertainty:• lead time to supply

• quantity supplied

• quality of supply

• data accuracy on products supplied and prices.

2. Procurement



2. Procurement 2.2. Principal Issues2.2.4. Selecting a Supplier

In selecting a supplier, a number of factors mustbe analyzed:

• price

• quality

• reliability

• credit terms

• shipping costs.

Look at the whole transaction cost of dealing witha supplier (not just the cheapest price).



2.1. Principal Issues2.2.5. Positive Trends (1)

Positive trends in purchasing and procurementinclude:

• reduced number of suppliers

• long-term relationships with suppliers

• suppliers located close to customers forimproved access

• integrated information infrastructure: EDI,electronic catalogs

2. Procurement



2.1. Principal Issues2.2.5. Positive Trends (2)

• suppliers considered to be an essential part of thebusiness

• suppliers involved in future product developmentprograms.

2. Procurement



2. Procurement 2.3. Analysis

Key considerations in analyzing the purchasingprocess:

• annual sales

• annual purchases

• number of suppliers

• number of supplier alliances

• total number of purchased products or parts

• short and long-term cost effective purchasing

• efficient business management of the purchasingprocess.



2. Procurement 2.4. Suggestions

Analyze what the suppliers requirements are for:• goods and services: lot sizes, packaging, delivery

frequency, and responsiveness

• information: how much and when

• financing arrangements and costs.

Compare your needs and abilities against theserequirements.



D%=100-(L*100)/S

2. Procurement 2.5. Performance Indicators2.5.1. Delivery to Schedule

The following formula is used to assess suppliersdelivery to schedule performance.

D = monthly delivery performance (%)L = number of line items delivered later thanscheduled

S = number of line items scheduled for deliveryduring month

Different tolerances for A, B, C-articles (see

chapter 6)



Q%=100-(R*100)/N

2. Procurement 2.4. Performance Indicators2.5.2. Quality to Specification

The following formula is used to assess qualityperformance.

• Q = monthly quality performance (%)

• R = number of units rejected during month

• N = number of units delivered during month




3. Sales Forecasting

3 1 K C3 S l



3.1. Key Concepts

Sales forecasting isthe process of organizing and analyzing

information in a way that makes it possibleto estimate future sales.

3. SalesForecasting

3 2 P i i l I3 S l



3.2. Principal Issues3.2.1. Demand Uncertainty

Elements of demand uncertainty:• timing of order

• size and composition of order

• data accuracy on:

• products required• delivery points

• timing.

3. SalesForecasting

3 S l 3 2 P i i l I



3. SalesForecasting

3.2. Principal Issues3.2.2. Components of Demand

Components of demand:• Trend:

• growth or decline over an extended period of time

• Cyclical:

• wavelike fluctuation around the trend• Seasonal:

• pattern of change that repeats itself year after year

• Random:

• not accounted for by the other components (trend,cyclical, or seasonal).

3 2 P i i l I3 S l



3.2. Principal Issues3.2.3. Sales Forecasting Methods (1)

Qualitative sales forecasting methods rely more on judgment and intuition than on historical data:

• surveys of buyer intentions, such asquestionnaires, telephone polls, and consumer

interviews• Delphi technique:

• a body of experts, consulted separately, is asked toarrive at a consensus opinion

• sales force composite:• based on the combined estimates of experienced salespersonnel.

3. SalesForecasting

3 Sales 3 2 Principal Issues



3. SalesForecasting


Quantitative sales forecasting methods make useof past data to predict future sales:

• market tests to gauge consumer response(usually to a new or modified product) underactual conditions

• trend projections/analysis (also called Time Series ) involves forecasting sales based on thehistorical relationship between sales and time,

which is expressed as a growth rate (percentage)and each measure is plotted on a growth curve :




3. SalesForecasting


• moving average: all observations are given equal weightand only a few of the previous observations areconsidered

• exponential smoothing: gives greater weight to morerecent observations and considers all past observations

• regression analysis can be used to forecast adependent variable (i.e., sales) as a result ofchanges in one or more independent variables(i.e., advertising)




3. SalesForecasting


• input-output models forecast the impact of thechange in the outputs (sales) of one industry onthe out-outs of the purchasing industry (i.e., areduction in the supply of tin cans produced bythe metal industry would effect the supply of

canned tuna that would be produced by the fishcanneries).




3. SalesForecasting


Computerized forecasting models include:• spreadsheets, such as Microsoft Excel (with the

Data Analysis Toolpack ) and Lotus 123, that canperform calculations automatically with changesin entered data

• forecasting application software:

• statistical packages, such as SAS, MYSTAT, and Minitab

• forecasting packages specifically designed for

forecasting applications, such as Forecast X, SAS,Forecast Pro.




3. SalesForecasting

3.2. Principal Issues3.2.4. Major Uses of Sales Forecasts (1)

Sales forecasts are used for:• production:

• production scheduling

• inventory control

• purchasing:• determination of procurement requirements

• scheduling of purchases to get favorable prices




3. SalesForecasting


•marketing:• formulation of marketing strategies for products

• setting of sales quotas

• scheduling of advertising expenditures and salespromotions

• personnel:• planning of manpower requirements

• finance:

• establishing of operating budgets

• cash flow planning• capital budget / expenditure decisions




3. SalesForecasting


• top management:

• overall planning and control of operations of thecompany.

3 2 Principal Issues3 Sales



3.2. Principal Issues3.2.5. Advantages Forecasting (1)

Accurate sales forecasting offers severaladvantages:

• reduced excess inventory

• fewer stock shortages which result when demand

exceeds supply• fewer unnecessary production line changes to

fulfill unanticipated demand

• less overtime hours through improved predictions

in personnel requirements

3. SalesForecasting

3 2 Principal Issues3 Sales



3.2. Principal Issues3.2.5. Advantages Forecasting (2)

• improved customer service levels as supply anddemand balance

• more economic purchasing power.

3. SalesForecasting




3. SalesForecasting

3.2. Principal Issues3.2.6. Forecast Accuracy

Factors that influence forecast accuracy:• availability of product demand history

• capability of computer system

• other available history (i.e., new products, design

changes, changes in customer base, promotionalactions, economic indicators)

• responsibility for forecasting: a team effort isrequired (Sales, Distribution and Manufacturing).

3 Sales 3 3 Checklist



3. SalesForecasting

3.3. Checklist

Sales forecasting considerations:• What are the items to be forecast?

• How far into the future should the forecastextend?

• What is the length of the time period for statingthe forecast quantity?

• How frequently should the forecast be made,reviewed and revised?

• What would constitute an acceptable tolerance offorecast error?

3.4. Suggestions (1)3. Sales



3.4. Suggestions (1)

Prior to forecasting sales, scrub the data byremoving the effects of unusual events that are notlikely to happen again. Otherwise, the forecastingmodel will show a distorted view of the past.

3. SalesForecasting

3.4. Suggestions (2)3. Sales




Examples of problems that may require dataadjustments:

• unusual weather

• addition or loss of major customers

• special promotions• changes in price or package size.

3. SalesForecasting

3. Sales 3.4. Suggestions (3)



3. SalesForecasting


Determine the most accurate forecasting method:• regularly use a number of different methods to

generate forecasts

• maintain historical accuracy information on each

method• use the most accurate method to generate

“official” forecasts.

3. Sales 3.4. Suggestions (4)



3. SalesForecasting


Make an ABC-analysis of the items to forecast:• A-items are reviewed each month by management

• only those B- and C-items with a significantdeviation between forecast and actual demand

need to be reviewed by management.




4. Production planning and control

4. Production 4.1. Key Concepts



Controly p

4.1.1. Production Planning and Control

The responsibility for:• number of units of a specific product to be

produced

• time intervals over which production will occur

• availability of equipment, materials and workforce

• cost effective inventory and resourcemanagement.

4. Production 4.2. Principal Issues



Controlp

4.2.1. Production as a Goal or Means (1)

Production as a goal:• resources are planned and used in the production

process regardless of actual demand

• often based on economies of scale, where lower

cost per item is presumed to generate endproduct demand.




Controlp

4.2.1. Production as a Goal or Means (2)

Production as a means:• resources are planned and used in the production

process only as a result of product demand

• often based on economies of scope, where end

product demand has greater influence overproduction units and costs.




Controlp

4.2.2. Economies of Scope vs Scale (1)

Economies of scope production assumptions:• responsive to demand

• flexible production plans

• variable cost per item

• smaller production runs• increased total set up and change over costs

• lower product/inventory obsolescence

• minimized inventory carrying costs

• material is pulled through the production processas needed.




Control 4.2.2. Economies of Scope vs Scale (2)

Economies of scale production assumptions:

• responsive to profit margin gains

• fixed production plans

• lower cost per item

• larger production runs• less production set up and change over cost

• greater risk of product/inventory obsolescence

• higher inventory carrying costs

• material is pushed through the productionprocess.




Control 4.2.3. Order Decoupling Point

How far does a customer order penetrate in theproduction process?

Purchasing Production Warehouse Distribution

Manufacture tostock

Manufacture toorder

Position of the order decoupling point

4.2. Principal Issues4. Production



4.2.4. Planning Hierarchy

Aggregate plan: works with aggregate (grouped) units

Master Production Schedule: indicates the quantity and timingof the production of specific end items.

(actual orders are incorporated)

Materials planning: what material is needed when?

Capacity requirements planning: which equipment, work forceand facilities are required?

Loading: which job on which work center?

Sequencing: in which order have the jobs to be processed?

Control



4. Production 4.3. Suggestions



Control

Suggestions:• pull rather than push material through theproduction process

• produce nothing until it is needed

• reduce set up times• reduce lot sizes

• try to move the order decoupling point to an earlystage in the supply chain

• try to remove transaction (steps which ad novalue) from the process.




5. Material Handling

5.1. Key Concepts5. MaterialH dli



5.1.1. Material Handling (1)

Material Handling:• moving of goods between incoming transport,storage, processes and outgoing transport

• the set of activities that move production inputs

and other goods within plants, warehouses andtransportation terminals.

Handling

5.1. Key Concepts5 1 1 M i l H dli (2)

5. MaterialH dli



5.1.1. Material Handling (2)

Providing the right amount of material:• in the right condition

• at the right place

• at the right time

• in the right position• in the right sequence

• for the right cost

• by using the right methods.

Handling

5. MaterialH dli

5.2. Principal Issues5 2 1 M t i l H dli M (1)



Handling 5.2.1. Materials Handling Manager (1)

The task for the materials handling manager is tofind the methods, the routes, the layouts and theright components to minimize handling.

5. MaterialHandling

5.2. Principal Issues5 2 1 M t i l H dli M (2)



Handling 5.2.1. Materials Handling Manager (2)

Six main responsibilities of the materials handlingmanager:

• packaging - unitizing

• internal transport

• storage• retrieval

• identification

• communication.

5. MaterialHandling

5.2. Principal Issues5 2 2 M t i l H dli S t D i



Handling 5.2.2. Material Handling System Design

The design of a material handling system dependsupon the the type and the characteristics of thematerials to be handled.

5. MaterialHandling

5.2. Principal Issues5 2 3 M t i l H dli S t C t (1)



Handling 5.2.3. Material Handling System Components (1)

Material handling equipment:• unitizing equipment

• material transport equipment

• storage and retrieval equipment

• automatic identification and communicationequipment.

5. MaterialHandling

5.2. Principal Issues5 2 3 Material Handling System Components (2)




Unitizing equipment:• containers, such as cartons, boxes, and bags

• carriers or support, such as pallets, skids, andplywood

• stretch wrap• shrink wrap.

5. MaterialHandling





Material transport equipment:• conveyors (belts and rollers)

• industrial vehicles, such as pallet trucks, lifttrucks, and automated guided vehicles (AGV)

• monorails• hoists

• cranes.

5. MaterialHandling





Storage and retrieval equipment:• unit load storage equipment

• unit load retrieval equipment

• small load storage and retrieval equipment.

5. MaterialHandling





Automatic identification and communicationequipment:

• bar coding

• radio frequency tag

• magnetic stripe• smart cards

• voice headsets

• machine vision.

5. MaterialHandling

5.2. Principal Issues5 2 4 Cost effective Means of Transport (1)



Handling 5.2.4. Cost-effective Means of Transport (1)

Key factors to consider in selecting means oftransport:

• physical characteristics of loads

• the number of loads to be moved

• the distance to be moved• the required speed of movement.

5.2. Principal Issues5 2 4 Cost-effective Means of Transport (2)

5. MaterialHandling



5.2.4. Cost-effective Means of Transport (2)Handling

Movement distance (m)

Unitsmoved/hour Conveyors Motorized trolleys

Forklift trucks

Manual trolley

Manual

5. MaterialHandling

5.2. Principal Issues5 2 4 Cost-effective Means of Transport (3)



Handling 5.2.4. Cost-effective Means of Transport (3)

Other factors which influence the means oftransport:

• cost of building/dismantling loads

• packaging costs

• space requirements• interface with other storage, transport and

handling systems

• housekeeping issues.

5. MaterialHandling

5.2. Principal Issues5 2 5 Warehousing (1)



Handling 5.2.5. Warehousing (1)

The warehouse must be:

• located in the right place

• the right size

• organized

to allow:• efficient delivery and placing

• cost-effective use of its space

• adequate access to stored materials

• security from theft and weather• flexibility to deal with the various items.


5. MaterialHandling



5.2.5. Warehousing (2)Handling

The mission (or goal) of a warehouse is set bydemand. The warehouse location is a means toachieving the mission.

Mission Location Demand

Balance and buffer Near the manufacturer Monthly/quarterly replenishments

of stocks

Accumulate and consolidate Central to production locations Weekly/monthly orders

Rapid response Close to customer Daily

5. MaterialHandling





Within the warehouse, stock must be:

• put into known places and

• in known order

so that it can be:

• retrieved quickly and in the right quantity• rotated properly (ex. first-in, first-out).

5. MaterialHandling

5.2. Principal Issues5.2.5. Warehousing (4)




Warehousing activities:

• receiving goods

• identifying goods

• sorting goods

• dispatching goods to storage• holding goods

• picking goods

• preparing shipments

• dispatching shipments.

5. MaterialHandling

5.3. Suggestions



Handling

Suggestions for materials handling:

• use identification systems, such as bar coding tohandle the right material:

• give a part identification number

• give a location identification number

• handle similar materials, packaging and size ofloads at the same time

• implement improvements in material handlingsystems which will increase the efficiency of the

overall system.




6. Inventory Management

6. InventoryManagement

6.1. Key Concepts



g

Inventory:

• those stocks or items used to support productionand customer service.

Service level:

• probability (%) that stock will be available to meetdemand.


6.2. Principal Issues6.2.1. Types of Inventory (1)



g 6 ypes o e to y ( )

Types of Inventory:

• raw materials:

• purchased parts used in manufacturing other items

• work-in-process:

• parts that are in the manufacturing process

• sub-assemblies:

• manufactured parts that are partially completed andstocked in inventory




6.2. Principal Issues6.2.2. Functions of Inventory (1)



g y ( )

Functions of inventory:

• safety stocks:

• protect against uncertainties of materials supply andconsumer demand

• cycle stocks:

• result from ordering or producing in lots

• transit stocks:

• materials must be moved from one location to another


6.2. Principal Issues6.2.2. Functions of Inventory (2)



y ( )

• speculative stocks:

• expected price increase

• promotional stocks:

• additional inventory accumulated for a promotionalevent.

6.2. Principal Issues6.2.3. Elements of Inventory (1)




y ( )

Safety stock

Excess stock

Replenishments

InventoryLevel

Time

Elements of inventory


6.2. Principal Issues6.2.3. Elements of Inventory (2)



y

Elements of inventory

Over time, demand and the ability to servicedemand (replenish inventory) can vary. Forecastsmay not be precise due to uncertainties, so, areserve of stock (safety stock) may be necessary to

reduce inventory shortages (stock-outs). Inventorylevels above the safety stock and normal demandare considered excess inventory.


6.2. Principal Issues6.2.4. Inventory Holding



Reasons for holding inventory:

• purchased parts:

• variations in supplier lead time

• quantity discounts

• price changes

• scarcities of materials

• manufactured parts:

• cover period between production runs

• allow flexibility in production scheduling

• variations in product demand (safety stock)• economies of scale.


6.2. Principal Issues6.2.5. Inventory Costs (1)



Cost of inventory production and holding:

• order/set-up costs:

• cost of replenishing inventory through changes in theproduction run for a different item

• includes labour and other associated costs

• carrying costs:• cost of capital

• insurance costs

• costs of space, staff

• inventory handling, deterioration, damage,obsolescence, insurance


6.2. Principal Issues6.2.5. Inventory Costs (2)



• opportunity costs:

• restriction of other investments that could have beenmade with the same money

• stock-out costs:

• lost sale

• halted production.


6.2. Principal Issues6.2.6. Inventory Management (1)



Objectives of inventory management:

• minimize costs:

• working capital

• carrying costs

• scrap and rework

• highest level of customer service.





Inventory management tasks:

• make decisions about:

• safety stock

• replenishment production runs

• excess stock.





Inventory must be managed differently for:

• independent demand: influenced by marketconditions

• dependent demand: derived from the productionof parent items.

(see following slide)





A

B C

D E

Independent demand

Dependentdemand

6.2. Principal Issues6.2.7. ABC-Analysis (1)




ABC analysis of inventory:• select a criterion (sales / usage) based onimportance

• rank the inventory items on criterion

• calculate the cumulative sales and/or usage for allitems

• assign items into A, B, C groups

• assign inventory levels and warehouse locations

for each item.





ABC classification, where items are not of equalimportance:

• A-items

• few items (ex. 15 %) which have a high rate of usageand/or high unit cost and account for 80 % of the total

value of usage in the inventory

• B-items

• number of items (ex. 25 %) which in total account for 15% of the total value of usage





• C-items

• great many items (ex. 60 %) with low individual usageand/or low unit value which in total account for only 5 %of the total value of usage





ABC analysis chart demonstrates relativeimportance of inventory items.

Class of Item % of Items % of Value

Class A 15% 80%

Class B 25% 15%

Class C 60% 5%





ABC - Analysis Chart

0

100

200

300

400

500

600

Product 1 Product 2 Product 3 Product 4

N u m b e r o f i t e m s

C

B

A


6.2. Principal Issues6.2.7. ABC Analysis (6)



ABC and inventory control efforts:

• A-items

• very careful management

• careful estimates of future usage.

• B-items

• routine management

• routine effort in forecasting demand.

• C-items

• little effort in forecasting demand

• however be careful for strategic items (safety stock).


6.2. Principal Issues6.2.8. Inventory Management Systems (1)



Inventory management systems include:

• two-bin replenishment system:

• used for low value , non-critical items (i.e.. class C items)

• relies on visual inspection of declining inventory

• one bin contains enough material to meet needs

between the time one order is received and another isplaced

• second bin (also called the “reserve bin”) contains

enough material to meet needs between placing an orderand receiving the materials

• if production taps into the reserve bin, additionalmaterials must be ordered immediately





• reorder point system:

• amount ordered when inventory declines to apredetermined level

• considers:

• when to order (re-order point)

• how much to order (order quantity)

• periodic review systems:

• after predetermined fixed passages of time, orders areplaced for variable amounts

• consider:

• how much to order (order quantity)• how long between orders (reorder time interval)





• Materials Requirements Planning (MRP):

• assumes variable demand throughout production

• calculates component requirements based on the MasterProduction Schedule (MPS), Bill of Material andinventory data

• materials are purchased only when the MPS has themscheduled for use

• materials are pushed through a plant





• MRP II systems share information with other functional

departments, outside the operations area (i.e.,purchasing, sales, cost accounting). These systems planthe use of company resources, including scheduling rawmaterials, vendors, production, equipment andprocesses

• JIT: different approach to reordering:• activities that add no value are waste

• material only is supplied when it is requested from thenext step in the production process (pull system)

• these requests are called kanbans.


6.2. Principal Issues6.2.9. How Much to Order: EOQ (1)



Economic Order Quantity (EOQ):

• the lot size that minimizes total annual inventoryholding and ordering costs

• assumptions:

• annual demand is constant.

• forecast is perfect (no random error)

• all costs are constant and linear

• lead time is known and constant.





Q - Lot size of the order H - Average annual

holding cost per unit

D - Annual demand S - Cost per order

Annual

carryingcost

Annual

orderingcostTotal cost = +

Q 2

H D Q

S TC = + --

Q/2 = Average inventory on hand

D/Q = Number of orders

per year





The Total-CostCurve

Ordering Costs

QO Order Quantity(Q) (optimal order quantity)

Holding costs

Q =2DS

H

=2(Annual Demand )(Order or Setup Cost )

Annual Holding CostOPT

Cost





Economic Order Quantity (EOQ): variations• quantity discounts: product cost is function of theorder quantity

• variations in demand: safety stock

• variations in lead time: safety stock.

6.2. Principal Issues6.2.10. When to Order: ROP (1)




Reorder point (R.O.P.)

R.O.P. = (D/W) * LD: annual demand W: working days L: lead time

ROP

time

Q

L

6.2. Principal Issues6.2.10. When to Order: ROP (2)




R.O.P. with uncertainties in demand, lead time and

supply: safety stockR.O.P. = (D/W) * L + SS

ROP

time

Q

L

Safety Stock

6.2. Principal Issues6.2.11. Safety Stock




Level of safety stock with a set service level:

• track historical sales to find:

• average

• standard deviation

•establish % service level

• find Z-score from distribution table

• SS = (Z-score) * Standard Deviation

6.2. Principal Issues6.2.12. Excess Inventory




Reasons for excess inventory include:

• engineering changes

• spoilage

• defects

• technical obsolescence• lack of market demand.


6.2. Principal Issues6.2.13. Inventory Counting Methods (1)



Inventory Counting Methods:

• Cycle counting:

• a few experienced people count continuouslythroughout the year

• timely detection of errors

• fewer mistakes in item identification• minimal loss of production time

• systematic improvement of record accuracy.

6.2. Principal Issues6.2.13. Inventory Counting Methods (2)




• End of year:

• many inexperienced people count inventory in a shorthectic period once per year

• no correction or cause of errors

• many mistakes in item identification

• plant and warehouse shutdown for inventory

• no improvement of inventory accuracy.


6.3. Suggestions6.3.1. 6 Step Action Plan



• Find out why you have inventories

• Analyze the present situation:

• inventory matrix (slide 6.3.2)

• ABC-analysis

• Define the inventory levels

• Define the inventory system

• Define performance indicators

• Performance follow-up


6.3. Suggestions6.3.2. Inventory Matrix



Fill in the different amounts of inventory

Raw material WIP Sub-assemblies MRO Finished Goods

Safety

Cycle

Transit Speculative

Promotional

-------

-------

6.3. Suggestions6.3.3. Rationalize Products




• Print and analyze lists of slow-moving and Class

C items• Monthly evaluation

• Action plans

• Follow-up

6.3. Suggestions6.3.4. Reduce Excess




Reduce excess:

• try to move the order decoupling point to an earlystage in the supply chain to reduce inventoryholding (carrying) cost:

• ABC - item management

• shorten replenishment cycles.

Sourcing Production Warehouse Distribution

6.4. Performance indicators (1)6. InventoryManagement



Inventory turnover:

Stock coverage:

• stockholding x 52 weeks / annual usage

Customer satisfaction:

• comparison of % of demand actually satisfiedwith the defined service level

• number of backorders

Annual cost of salesInventory value at cost

6.4. Performance indicators (2)6. InventoryManagement



Excess inventory reduction:

R=inventory reduction during month (%)PE=prior month excess inventory (value)

CE=current month excess inventory (value)

R%=((PE - CE)/PE)*100




7. Distribution

7. Distribution 7.1. Key Concepts (1)



Physical distribution:

• the activity that is concerned with:

• receiving parts or finished goods

• storing them until they are required

• and then delivering them to the customer.




Transport operator:

• who does the moving.

Intermodal:

• interchange point from one transportation mode

provider to another.




Consolidation:

• the process of receiving multiple lots in smallquantities, which are accumulated and thenrepackaged into one larger lot.

Cross docking:

• unloading the cargo from several trucks and thenimmediately reload it into one container fordelivery to a final destination.




Distribution warehouse:

• a facility designed to assemble and thenredistribute goods in a way that facilitates rapidmovement to customers.

Unitization:

• a technique for grouping boxes on a pallet or skidfor later movement by pallet jack, forklift,conveyor and/or truck.




Containerization:

• the process of combining several unitized loadsinto a single well-protected load.

7. Distribution 7.2. Principal Issues7.2.1. Functions of Physical Distribution



Functions of physical distribution:

• inventory management

• order processing

• warehousing:

• the set of activities involved in receiving and storinggoods and preparing them for reshipment

• materials handling

• transportation.

7. Distribution 7.2. Principal Issues7.2.2. Distribution Decisions



Important distribution decisions:

• Which transport mode?

• Number and location of distribution warehouses?

• Own or contract-out warehousing and transport?

7.2. Principal Issues7.2.3. Transport Modes (1)

7. Distribution



Basis of transport mode selection:

• nature, volume, value and criticality of goods

• flexibility of transport mode: coping with demandchange.


7. Distribution



Methods of transport:

• trucks

• railroads

• water

• airways• pipelines

Rail

Truck

PipelineWater

Air

Piggyback Birdyback

Fishyback

7. Distribution 7.2. Principal Issues7.2.3. Transport Modes (3)



Trucks:

• flexible, on-time, low loss and damage, tracing,accuracy and wide geographical coverage

• weather and traffic conditions can delayshipments

• still heavy price competition.


7. Distribution



Railroads:

• inexpensive for carload lots

• requires more packing material or must allow forrough handling

• somewhat slow

• freightforwarders, piggyback truck, anddoublestack containers offer cost savings forusers.


7. Distribution



Water transportation:

• ideal for heavy, low-value non-perishables, buthas high fixed costs

• weather can be a problem

• containerization and improved ports allow for

expansion in new products and markets.


7. Distribution



Airways:

• high costs, so only suitable for high value orurgent or perishable items

• weight and locations limited

• saves inventory holding costs

• important in international trade.


7. Distribution



Pipelines:

• slow but dependable, continuous flow of liquidsor slurries

• harder to establish today due to governmentregulations.

7. Distribution 7.2. Principal Issues7.2.4. Outsourcing



Decisions for owning or contracting-out transport

consider:• total cost

• control

• customer service• flexibility

• management skills

• operators

• return on investment.

7. Distribution 7.2. Principal Issues7.2.5. Distribution Warehouses



Number and location of distribution warehouses

are based on:• customer service needs

• available transportation services

• cost trade-off.

7. Distribution 7.3. Performance indicators



Performance can be assessed on the basis of:

• distribution system flexibility:

• response time to special requests

• distribution system information:

• speed, accuracy and message detail of response

• distribution system malfunction recovery:

• efficiency to recover from malfunction (errors in billing,damage, claims).



8.1. Key Concepts8. CustomerService



A statement of goals and acceptableperformance for the quality of service

that a company expects to deliverto its customers.

Customer Service Standard

8. CustomerService

8.2. Principal Issues8.2.1. What Customers Look for (1)



What customers look for:

• Pre-transaction:

• accessibility of data (catalogue, price lists, literature)

• completeness of data (products, prices, instructions)

• availability of samples

8. CustomerService




• accessibility of the organization:

• experts• assurance of product suitability, quality, reliability

(employees should be knowledgeable about products)

• customers want to be noticed, appreciated andrecognized as important individuals

• efficiency of the information flow

8. CustomerService




• Transaction:

• reliability: delivery on time, in the right quantities, anderror-free

• quality of products, packaging, palletisation

• information about order processing, dispatch, transport

• flexibility: time, product variants, volumes

• assurance of satisfaction after purchase.

8. CustomerService




• Post-transaction:

• technical support, training, helpdesk• availability of spare parts and repair instructions

• product traceability

• handling of complaints: speed, monitoring, evaluation

• administration: invoices, accounts receivable, andpayments

• performance measurements and evaluation.

8. CustomerService

8.2. Principal Issues8.2.2. What Customers Experience (1)



The customer experience is:

• any episode in which the customer comes incontact with the organization:

• personal contact

• telephone

• mail• advertising

• internet (i.e., e-mail, forms)

• any event that forms a perception of the

organization in the mind of the customer.



8.2. Principal Issues8.2.3. What Customers Want

8. CustomerService



Fill in this table for all of your products

Customer

wants

Product

offered

Product

characteristic

Performance

measure

Performance

target

Fast car Sports car Speed mph

8. CustomerService

8.2. Principal Issues8.2.4. Customer Service Issues



Customer service issues include:

• accurate understanding of customer’s needs and

wants

• the ability to deliver necessary customer servicelevels

• variations between plans and their actualimplementation

• effective communications with the customer’s

• difference between supplier’s and customer’s

perception of service level.

8. CustomerService

8.2. Principal Issues8.2.5. Service Levels



Which service level approach to you use:

• cut costs and reduce or eliminate service

• maximum service at any cost

• the cost of stock-out is no greater than the cost ofcarrying additional inventory (break-even point)

• competitive advantage, where service issufficiently higher than competitors’ service.

8. CustomerService

8.3. Analysis8.3.1. Customer Analysis (1)

Customer Analysis: example table:



Sales (value) % Total Sales % Cumul Products What the customer wants

Customer 1 92000 18,4 18,4 A 3 days ex stockCustomer 2 83500 16,7 35,1 A (75%), B(25%) 2 weeks

Customer 3 73200 14,6 49,7 B 5 days ex stock

Customer 4 31500 6,3 56,0 C 6 weeks order to delivery

-------

-------

-------

-------

Total Sales 500000

Customer Analysis: example table:

The following table helps to identify the customergroups, their primary expectations, and theircontribution to total sales.

8. CustomerService


Pareto Analysis:



Pareto Analysis:

• in many cases, approximately 80% of the turnover(i.e., stock) can be ascribed to approximately 20 %of the customers, articles or orders

• Rank the customers, products, etc. in order of

magnitude• Calculate % that each item contributes to total

value

• derive a cumulative % list

• evaluate the cumulative list and identifyappropriate breakpoints (A, B and C).

8. CustomerService




8. CustomerService

8.3. Analysis8.3.2. Know the Customer



Know the customer:

• Who is our customer?

• What are the important things we know about ourcustomers?

• What do our customers expect?

• What do our customers want?

8. CustomerService

8.3. Analysis8.3.3. Customer Service Levels



Customer service levels:

• Do we consistently meet and exceedexpectations?

• How well do we solve the problems that ourcustomers experience?

• What service levels will give us a relative edgeover our competitors?

• How, and how quickly, are we using customerinformation?

8. CustomerService

8.3. Analysis8.3.4. Customer Response



Customer response

• What did you like most/least about doingbusiness with us?

• What will you tell others about us?

• How can we serve you better?

8. CustomerService

8.4. Suggestions

G ( t ) t b d i



Group (segment ) customers based on service

needs:• Companies traditionally group customers by

industry or product, and then provide the samelevel of service to everyone within the group.

• To improve customer satisfaction, customersshould be grouped by distinct service needs andservices should be tailored to each group.

8. CustomerService

8.5. Performance Indicators8.5.1. Customer Service Level

C



Customer service level

• The desired probability versus the actualpercentage that product demand can be met fromstock

• expressed in a number of ways:

• % of orders completely satisfied from stock

• % of units demanded which are met from stock

• % of units demanded which are delivered on time

• % of time there is stock available

8. CustomerService

8.5. Performance Indicators8.5.2. Availability

P f i di f il bili



Performance indicators of availability:

• stock-out frequency:• how many times does demand for a specific product

exceed its availability

• fill rate:

• how much of a specific product is available to satisfycustomer demand

• orders shipped complete:

• how often is customer demand fully met.

8. CustomerService

8.5. Performance Indicators8.5.3. Operational Performance

O i l f i di



Operational performance indicators:

• speed:• order cycle time

• flexibility:

• ability to handle extraordinary customer requests

• malfunction recovery:• contingency plans for recovering from service failures.

8. CustomerService

8.5. Performance Indicators8.5.4. Reliability

R li bili f i di



Reliability performance indicators:

• ability to comply to:• planned inventory availability

• operational performance

• capability and willingness to:

• provide accurate and timely customer logisticalinformation

• commitment to:

• continuous service quality improvement.

8. CustomerService

8.5. Performance Indicators8.5.5. Quality

Q lit f i di t



Quality performance indicators:

• Ability to deliver:• items without errors

• shipped goods without damage.

The End



The End

Supply Chain Management Guide

Please forward any comments to: [email protected]

Internet: http://www.managementsupport.com

Main trucking image © 1999 www.arttoday.com

All intellectual contents Copyright © Imants

http://www.managementsupport.com/

http://www.managementsupport.com/

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