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Team RowlandPresenter 1: Elizabeth Rowland (E.R.)Presenter 2: Juan Guerrero (J.G.)Presenter 3: Tarun Aggarwal (T.A.)Presenter 4: Norihiko Hosokawa (N.H.)
Implement
Define
Measure
Analyze
Control
Implement
Six Sigma DMAIC Methodology (E.R)
Eaton Corporation(E.R)
• Power management company• 102,000 employees• $22 billion sales in 2013• Customers in 175+ countries• Four main business sectors– Electrical, Aerospace, Vehicle, and Hydraulics
Define Measure Analyze Implement Control
Define Measure Analyze Implement Control
Eaton Corporation: Sector of Focus(E.R)
• Power management company• 102,000 employees• $22 billion sales in 2013• Customers in 175+ countries• Four main business sectors– Electrical, Aerospace, Vehicle, and Hydraulics• Customer Manufacturing Solutions Centers (CMSCs)
• CMSCs must improve their supply chain network by:– Reducing premium freight frequency – Managing overall inventory
• CMSCs must increase their future growth sustainability
Define Measure Analyze Implement Control
Problem Definition(E.R)
Define Measure Analyze Implement Control
Measurement(E.R)
Define Measure Analyze Implement Control
Measurement(E.R)
6/99/13
WEST USA: High inventory levels and high premium shipped
orders
Measurement(E.R)
Analysis Part I: Transportation Cost (J.G)
Define Measure Analyze Implement Control
Sources
CMSC
Define Measure Analyze Implement Control
CMSC:• SE = Atl-Ral-Orl• NE = Bal-NJ-Cle-Har• MW = Chi-StL• S = Dal-Hou• SW = SF-LA-Pho• NW = Sea-Por• W = Den
Sources:• NC = Fayettville-Arden-
Raleigh• SC = Sumter-W34• LA = W87• Dallas = CDC&DBN* P.Rico & Others not included in analysis
Analysis Part I: Transportation Cost Short term
(J.G)
Define Measure Analyze Implement Control
Analysis Part I: Transportation Cost Short term J.G
Define Measure Analyze Implement ControlDefine Measure Analyze Implement Control
Analysis Part I: Transportation Cost Long term J.G
Define Measure Analyze Implement ControlDefine Measure Analyze Implement Control
Implementation & Control Part I (J.G) Recommendations• SHORT-TERM RECOMMENDATIONS:– Revise sourcing allocation
• Implement optimization models• Identify current & future bottle-necks• Reduce logistic costs due to sourcing changes
• RISKS & CONSIDERATIONS:– Verify Source capacities– Verify distances between Sources and CMSCs– Determine if production streamline can be achieved (1
source to 1 CMSC?)
Analysis Part II: Inventory Control (T.A)
Define Measure Analyze Implement Control
Define Measure Analyze Implement Control
Analysis Part II: Inventory Control (T.A)
Define Measure Analyze Implement Control
Kanban System
Analysis Part II: Inventory Control (T.A)
Define Measure
Analyze
Implement Control
Analysis Part II: Challenge at Hand (T.A)
Define Measure
Analyze
Implement Control
Improper Forecasting of demand Stock outs in CMSCs. Higher orders leading to increased lead times
Causes Effects
Shifting of demand to different facilities
Reduced capability to fix inventory to facilities
Basic reliance on truck and air for transportation
Truck transport results in longer lead time Air transport results in higher transport cost
Product shipment normally of LTL size
Increases number of shipments and adds to overall cost
Low Risk Moderate Risk High Risk
Analysis Part II: Challenge at Hand (T.A)
Supply Chain
1. Employ third party transportation to avoid LTL shipments
2. Consider shipping via rail routes
1. W87 to cater specifically to west coast CMSCs2. Increase buffer stock levels in W87 to reduce inventory
buildup in CMSCs
1. Function in parallel with west coast facilities to meet demand
2. Employ resource pooling to reduce safety stock build up
Process Optimization
1. Maintain the 3-day shipment cycle.2. Prioritize west-coast orders to counter higher lead timeProduction Plants
Consolidation & Transportation
W87 Distribution Center
New Distribution Centre
Analysis Part II: Facing the Challenge T.A
Define Measure
Analyze
Implement Control
Implementation: Options
Define Measure
Analyze
Implement Control
• Not small amount of capital expenditure
• Not easy to redesign supply chain
• Not easy to find the place
• Decrease lead time in Western area
• Decrease inventory levels in Western area
• Decrease frequency of premium freights
• Lower transportation costs
• Give flexibility to major warehouses
Option 1: Build New Warehouse (N.H)
Define Measure
Analyze
Implement Control
Option 2: Review Demand Forecast N.H
Define Measure
Analyze
Implement Control
Option 3: Verify Re-order Point (N.H)
• Decrease excess inventory and shortage
• Easy to implement
• Not necessarily eradicate shortage
• Not necessarily decrease lead time
Define Measure
Analyze
Implement Control
Identify location * Close to a major city* Coverage of CMSCs
Legal formalities* State Govt. regulations* Compliance
Design capabilities * Supply chain networks* Capacity
Construction* Shorter lead time* Better inventory levels at CMSCs
Implementation Plan (N.H)
Define Measure
Analyze
Implement Control
Control: Overcoming Potential Risk N.H
Define Measure
Analyze
Implement Control
Road to Success (N.H)
END
Additional Slides
Optimization Model
Optimization Model
Optimization Model