Professional Documents
Culture Documents
Program Objectives
By the end of this program, participants will be able to develop a clear understanding on: Supply chain management as a concept Globalization and its impact on supply chain management Corporate Strategy and Supply Chain Strategy and the need to align the two strategies Strategic importance of customer focus and the demand-driven supply chain Risk management strategies that focus on security and continuity of operations Use of corporate and supply chain strategy to drive supply chain decision making
What is Supply Chain Strategy? Is there a need to align Corporate Strategy & Supply Chain Strategy?
It is critical for you to understand these key concepts of Supply Chain Management Lets understand these concepts one by one
SCM is
According to the Council of Supply Chain Management Professionals (CSCMP), SCM encompasses the planning and management of all activities involved in sourcing, procurement, conversion and logistics management
It includes
It also includes the crucial components of coordination and collaboration with channel partners, which can be suppliers, intermediaries, third-party service providers and customers.
Now that we have defined what Supply Chain Management is Lets see how does a typical Supply Chain looks like
Producer
Products Power Professional services Government services Educational services
Customer
Retailer Wholesaler Distributor End user
Customer
Electric backup power Electric transformers Facility maintenance Programming services Janitorial services Electric Power Utility
Home customers
Commercial customers
After having looked at various types of supply chains Lets now identify key supply chain processes and see how a supply chain evolves
Value stream Processes that create, produce, and deliver a product or service Entities, functions within entities, and processes
Supply chain
Plan
Plan
Deliver Return
Source Return
Make
Deliver Return
Source
Make
Deliver Return
Source Return
Source Return
Make
Deliver
Return
Suppliers Supplier
Return
Customers Customer
Your Company
Return
Retail sales
Distribution
2: Semifunctional Enterprise
Mostly manual ops Inventory reduction in owned facilities New low-price purchasing strategies Some hard-skills training, job enhancement Enhanced marketing and forecasting No coordination of initiatives
3: Integrated Enterprise
New focus on process Internal process integration MRP/ERP Intranets, etc., across functions Design teams Enhanced warehousing, logistics, forecasting, etc.
4: Extended Enterprise
Process integration across entity boundaries Eventual electronic information connections among multiple partners ERP-to-ERP links E-commerce Supply chain vs. supply chain competition
Materials/products/ services
Payments
Suppliers suppliers
Suppliers
Internal chain
Customers
Customers customers
Materials/products/ services
Payments
Most resources are invested in creating the value of greatest importance to the market.
What is Globalization?
Globalization is a process of interaction and integration among the people, companies, and governments of different nations, a process driven by international trade and investment and aided by information technology.
Safexper t
You
The globalization of business is the best thing to happen to supply chain management (SCM) in the last 30 years. Driven by overwhelming market forces, globalization has forced countries and companies to become more efficient, creating the infrastructure and competitive advantage necessary to survive.
Safexper t
You
Delivered cost Logistics automation End-to-end visibility Supplier portals and advance notice Total ID and regulatory compliance Transportation flexibility Variability management Integrated workflows Integrated planning and execution Financial SCM
Globalization has indeed changed the scenario for Supply Chains Lets now look at what is Corporate Strategy and Supply Chain Strategy, the importance of aligning the two, and need to alter these
Corporate Strategy
Strategy: Demand-Driven Enterprise
Problem: Bullwhip Effect
Demand variability among end users increases at each stage in the chain because of inherent inaccuracies in each firms demand forecasts.
Corporate Strategy
Strategy: Number of Supply Chains
Suppliers Nucleus Firm Customers Functional products Innovative products
Supply chains for functional products need High average utilization rate Minimal inventory with high turns Short lead time Suppliers offering cost, quality Products with maximum performance, minimal cost.
Supply chains for innovative products need Buffer capacity (safety stock) Aggressive reduction of lead times Suppliers chosen for speed, flexibility, quality (less emphasis on cost) Modular design with postponement of differentiation.
Corporate Strategy
Supply chain versus supply chain
Scenario One Competition between groups of companies in completely distinct networks Scenario Two Competition between individual companies with different SCM capabilities Scenario Three Competition between channel masters with power to determine nature of supply network
Corporate Strategy
Building blocks of collaborative relationships
Information exchange and connectivity Deterrents to improper behavior Network-wide focus Network-wide visibility of inventory Trust-building processes Incentives to collaborate Sharing of knowledge, not only data Varied partner commitment types Collective management of inventory Visible sharing of benefits, burdens Leaders with authority
Corporate Strategy
Management tasks
4 3 2 1
Corporate Strategy
Barriers to collaboration
Sub-Optimization Each partner working for its own benefit, not the chains Misaligned Incentives Example: sales bonuses not based upon results at end-user level Working with Competitors Failure to treat competitor partners with caution Weak partner bottlenecks Limits imposed by slowest, least sophisticated partner
Corporate Strategy
Barriers to collaboration (continued)
Technology Barriers Incompatible ERP software, etc. Power-based relationships Rebellion of weaker partners against aggressive nucleus firm Underestimated benefits Example: measuring efficiency gains rather than focusing on ROI Culture conflicts Inability to see value of other ways of doing business
Design Characteristics
Ad hoc decisions, poorly planned meetings, little or no training, etc. Functional organization with each function in its own silo making
Stage II
separate decisions; possible automation, job enrichment, soft skill training Cross-functional teams focused on business wide process
Organizational Design Supply Chain Processes Systems and Technology People Supply Chain Metrics
Stage III
improvement; team training; cross-functional communication, automation Cross-company partnerships among process-oriented, integrated partners; global sourcing; executive-level direction
Stage IV
area
Working in teams with a cost management
Organizational Design Supply Chain Processes Systems and Technology People Supply Chain Metrics
specialist
Managed diplomatically Hired by HR with understanding of SC issues Championed by executive
Manage to Increase
Manage to Decrease
We have seen how we can strategically plan for organizational design, processes, people and metrics to align these with our SC strategy Lets now have a look on risk management strategies that focus on security and continuity of operations
Loss of customers
Assess Transportation failures Supplier failures Climate, weather Licensing, regulations Supply quality, liability Lost customers Theft, vandalism, etc.
Having looked at Risk Management Strategies to Improve Supply Chains Lets now see how we can use corporate and supply chain management strategies to drive supply chain decision making
SCM
We have seen how corporate and supply chain strategy drives supply chain decision making Lets now have a understand the sue of metrics to guide supply chain management
*Apply KPIs only to processes and activities based on corporate and supply chain strategies.
Financial Perspective Traditional Cash-to-cash, ROI, etc. Retrospective only Must always be present
Financial Perspective Goals Measures
Business Process Perspective Prospecting calls, productivity, etc. Also flexibility, waste reduction, other SC goals
Business Process Perspective Goals Measures
Innovation & Learning Perspective Formal staff training, management training, etc. Product or process innovations
Innovation & Learning Perspective Goals
-Measures
Level 1 Metric
Perfect order fulfillment
Order fulfillment cycle time Upside SC flexibility & adaptability Downside SC adaptability SC management cost Cost of goods sold Cash-to-cash cycle time Return on SC fixed assets
Effectiveness of organization in managing assets to support demand satisfaction, including management of all assets: fixed and working capital
Definition
Number of days an organization requires to achieve an unplanned sustainable 20% increase in quantities delivered
Calculation
Least amount of time required to achieve the increase considering source, make, and deliver components Largest sustainable quantity increase considering source, make, and deliver components Largest sustainable quantity decrease considering source, make, and deliver components
Upside SC Adaptability
All direct and indirect expenses Cost Cost to Cost to Cost to + + + associated with operating to Source Deliver Return SCOR business processes Plan across the supply chain Supply chain expenses not measured in supply chain management costs Cost of Goods Sold = Direct Material + Direct Labor + Overhead
Calculation
Return an organization receives on capital invested in supply chain fixed assets used in plan, source, make, deliver, and return activities
Supply Chain Revenue COGS Supply Chain Management Costs Supply Chain Fixed Assets
We have seen how we can measure the cost, asset management capabilities, flexibility, responsiveness and reliability of supply chains Lets now see the financial impact of supply chain management decisions on cost and profits
We now know about the various concepts of supply chain management including the management of financial performance Lets see what kind of leadership and management is required for managing supply chains effectively
S2
S1
C1
C2
Can manage critical relationships Understand the business model Decide based on analysis, fact Have cost management ability Understand e-business systems
Now, we are aware of the competencies required for managing and leading supply chains effectively Lets also study the impact of security and compliance issues on the supply chains
We are now aware about the impact of significant regulations on supply chains Lets now understand the concept of continuous improvement and how it can be used as a SCM Strategy
Continuous Improvement
Processoriented
Top-down direction
Neverending
Total Quality
Bottom-up implementation
Small steps
Root causes
Continuous Improvement
Continuous improvement model 1 2 3 4 Process analysis Process assessment Project planning Implementation and change management
Yes
No
Create invoice
Order fulfilled
Defect measurement
Straightforward counting of defects Customer defines defect Customer complaints Focus groups
Occurrence %
80
Pareto diagram
4
Shape
1 Etc.
We have looked at the Continuous Improvement Model as well how to increase visibility and analyze the root causes of problems in supply chains Lets now understand the concept and benefits of following benchmarking and continuous improvement strategies/ methods in SCM
JIT benefits
Cycle time reduction Inventory reduction Labor cost reduction Quality cost reduction Material cost reduction Improved vendor relationships
Lean principles
Topic Review
Key supply chain management processes Creating value through supply chain management Impact of globalization on supply chain management Aligning supply chain strategy with corporate strategy Competitive priorities and future direction Using ERP to align operations with strategy Supply chain risk management strategies Using corporate and supply chain strategies to set priorities and make decisions Elements of supply chain management
Topic Review
Supply chain performance metrics Managing the supply chain for financial performance Managing and leading people in the supply chain Synchronization and key success factors Security and compliance issues Visibility and analysis Goals and benchmarking Continuous improvement methods Implementation and change management
We have looked at the strategies for improving supply chains Lets now understand the role of Demand Planning in SCM
Demand
Seasonality
Partner collaboration
Reduce variability
Improve forecasts
We had an overview of Demand Planning Lets now look at the sources of variability in Demand
Maximum demand
Maximum demand
We have understood the sources of variability in demand and looked at supply chain dynamics Lets now learn about the Demand Forecasting process
Forecasting
Principles of forecasting
Forecasts are Necessary (sometimes) Wrong (almost always, and they should include an estimate of error) More accurate for product groups than for individual items More accurate for near term than for long term Not appropriate for dependent demand items.
Forecast Actual Monthly Demand
Forecasting
Qualitative approaches to forecasting demand
Personal insight Sales force estimate Management estimate Market research Delphi method Estimate made by one person with special experience, knowledge, or seniority Estimate given by entire sales force, to cover all customer types and to capitalize on market insights; may be overly optimistic Combined expertise of management; includes pyramid forecasting and historical analogy Systematic gathering and analysis of data about potential markets, sales, consumer attitudes, etc. Anonymous, repeated responses to questionnaires and comments by selected experts
When to use qualitative forecasting methods: For new products When hard data are lacking As a check on quantitative forecasts
Extrinsic
Based upon factors related to demand for product, such as Impact of housing starts on furniture sales Impact of population aging on demand for medication, assisted living, etc.
Forecasting
Intrinsic forecasting methods compared
Jan Actual demand Naive forecast 3-month moving average Weighted moving average Exponential smoothing 1,000 Feb Mar Apr 975 975 May Actual demand Naive forecast Moving average Weighted moving average Exponential smoothing
(Previous months demand) (Average of previous 3 months)
(975 + 1,125 + 950) 3 = 1,016.67 (1,017)
Method/Calculation
950 1,125
1,025
1,017
1,046
1,021
1,040* 1,027
*Previously calculated forecast
**Constant = 0.2
Deseasonalized Avg. Monthly Demand 1,055 1,055 1,055 1,055 1,055 1,055 1,055
1,260 1,250 1,270 1,325 1,250 1,125 1,005 1,115 1,125 975 950 1,000 950 940 950 940 935 975 983
1,083 1,042
Forecasting
Mean absolute deviation (MAD) with smoothing
Month May Jun Jul Aug Sep Oct Nov Dec Demand 4 3 2 5 10 15 25 32 Exponential Forecast with .4 Smoothing 14.00 10.00 7.20 5.12 5.07 7.04 10.22 16.13 Error (Deviation) 10.00 (4 14) 7.00 (3 10) 5.20 (2 7.2) 0.12 (5 5.12) +4.93 (10 5.07) +7.96 (15 7.04) +14.78 (25 10.22) +15.87 (32 16.13) Absolute Deviation 10 7 5.2 .12 4.93 7.96 14.78 15.87 65.86 (65.86 / 8 = 8.23)
NOTE: Absolute deviation measures the size of the errornot the directionand therefore has no +/ sign. WMAPE is replacing MAD in many organizations.
8.23
Forecasting
Standard deviation
Forecasting
Extrinsic forecasting techniques
Extrinsic forecasts are based upon factors related to demand for a product or service, such as leading or lagging economic indicators. Abstract Business Cycle Graph
Forecasting
Service sector forecasting
Service businesses, such as restaurants, may track seasonal demand in units as short as minutes.
20% Percentage 15% of sales by hour of day 10% 5% Lunchtime Dinnertime
11-12 12-1 1-2 2-3 3-4 4-5 5-6 6-7 7-8 8-9 9-10 Hour of day
We have a clear understanding on Demand Forecasting Process Lets now look at various collaborations among supply chain partners to facilitate successful Demand Planning
Types of Collaboration Information sharing (quick response program, or QRP) Retailer provides POS data to supplier. Customer (retailer) enters orders. Supplier synchronizes supply with demand but may still do own forecasting.
Types of Collaboration Continuous replenishment (CR) Retailer provides POS data to supplier. Supplier and customer collaborate on ship dates. Forecasts become more accurate, resulting in reduced inventory.
Vendor-Managed Inventory
Types of Collaboration
Measuring VMI success
Reduced inventory costs for the overall supply chain? Better on-time delivery percentage? Reduced or eliminated stockouts? Shorter lead time for deliveries? Increased inventory turns?
What is CPFR?
While we are talking about various types of collaborations among supply chain partners, CPFR is one of the types to facilitate Demand Planning. Its full form is Collaborative planning, forecasting, and replenishment
Safexper t
You
Retailer Tasks
Vendor Management Category Management POS Forecasting Replenishment Planning
Execution
Production & Supply Planning Logistics/Distribution Execution Monitoring Customer Scorecard Order Generation Order Fulfillment Buying/Re-buying Logistics/Distribution Store Execution Supplier Scorecard
Analysis
Exception Management Performance Assessment
Types of Collaboration
CPFR scenarios
Retail Event Collaboration
Planning and executing promotions, handling exceptions, evaluating performance for continuous improvement
DC Replenishment Collaboration
Joint order commitments, collaborative forecasting, joint order issuing, mutual order support to enhance VMI
Types of Collaboration
CPFR Benefits*
Increased sales Faster turns Improved inventory control Cost savings Improved in-stock and on-shelf Lower logistics costs
CPFR Challenges
Increased costs Resistance to data sharing Difficulties in bridging internal functions May be more difficult than collaboration among firms Hard for retailers to establish supplier-specific teams
*Studies by Kurt Salmon Associates and AMR. See www.vics.org for details.
We have a clear understanding on Demand Forecasting Process Lets now understand the role of marketing in Demand Planning
Finding markets Educating customers and SC Analyzing markets partners Refining product Pricing design Placement Packaging Branding
S3
S2
S1
Plant
C1
C2
C3
The Role of Marketing in Demand Planning is clear to us. Lets now look at Collaborative Design for the Supply Chains, the contribution of design to product cost and the delivery cost and the levels of supplier involvement
Cost overruns reduced because of efficient manufacture Approaches to design improved with supplier expertise Satisfaction enhanced with marketing, customer input Efficient transport, warehousing enhanced by innovation Quality for price improves with supplier input
Reverse product flow (reverse logistics)
S3
S2
S1
Plant
C1
C2
C3
Definition
Replace similar parts with a single part.
Replace multiple bolt sizes with one size. Modular design (see next slide).
Tradeoffs
Benefits
Lower cost for bulk purchase of identical parts Production streamlining Simpler, cheaper storage
Risks
Cost of production modifications Loss of design flexibility Possible reduction of fit, finish
Definition
Design identical components for use in all products in a family. RAM modules for computers Interchangeable camera lenses Shoe laces College courses
Tradeoffs
Benefits
Lower design cost for product family Production streamlining Expanded customer base More efficient logistics
Risks
Higher cost per product (lower for family) Loss of design flexibility Possible reduction of fit, finish
Definition
Design one product for multiple markets. Can combine with modularity (one base product with modules to adapt to markets). One size fits all and unisex clothing Cars, trucks with option packages for different market segments
Tradeoffs
Benefits
Increased sales volume potential Reduced cost of design, production compared to market-specific products
Risks
Potential loss of sales in each particular market Less perceived quality, style compared to specialized products Loss of customer loyalty
Definition
Delay final assembly of components into final products to increase ability to customize to customer specifications (assumes modularity). Option packages on automobilesfor consumer selection HPs assembly of printers at distributor, not factory
Tradeoffs
Benefits
Economies of scale More efficient, expert workers doing assembly Increased sales volume (more markets or segments) Reduced inventory costs
Risks
Investment costs for new equipment, training, etc. Possible friction with distributors over added tasks
Definition
Products developed in a manner that allows components to be used in other products; process is associated with green manufacturing. Caterpillars customerdriven replacement of heavy equipment parts
Benefits
Cost advantages: materials and resources Cost savings for customer Compliance with environmental laws
We have gained a clarity on collaborative design, levels of supplier involvement, various approaches and factors affecting the design of services Lets now understand the concepts, purposes and elements of Sales Plan, Sales and Operations Planning and Production Plan
Resource Planning
Demand Management
Sales and operations planning Sales plan Production plan Capacity Planning
and
Demand Management
Master scheduling
Sales and Operations Planning (S&OP) Contributions to sales and operations planning
Demand Side
Cooperation
Production Side
S&OP
Product groups
Sales and Operations Planning (S&OP) Monthly sales and operations planning process
Step 1 Step 2 Step 3 Step 4 Step 5 Data gathering Demand planning Statistical forecast updated Statistical forecast reviewed by sales and marketing
Supply planning Supply management team may alter operations plan if necessary Pre-S&OP Key players review data, set meeting executive meeting agenda Executive S&OP meeting VPs meet monthly to review decisions and strategy
July
1,000
August
1,200
Weeks MPSWeekly
production numbers for specific products LX30 30-ppm LX21 21-ppm LX15 15-ppm
50 75 50
50 25 150
50 100 150
75 75 150
75 100 75
75 100 125
50 100 150
MPS Focus
Schedule finished goods.
Make-to-order (MTO)
(Many items made from few components; e.g., custom products)
Assemble-to-order (ATO)
(Many end items, few components; e.g., computers assembled at or near point of sale)
1 2 3 4 5 6 7 8 9 20 22 21 25 24 23 21 21 25 19 17 15 11 9 5 2 1 0
DTF
PTF
0 27 50
6 35 10 50
PTF
5 43 50
1 49 50
0 27
6 35 10
PTF
We have understood the concepts of Sales Plan, Sales and Operations Planning and Production Plan. We have also gained a clarity on purpose and objectives of Master Production Scheduling. Lets now look at the purpose and elements of Material Requirement Planning
S&OP
Demand Mgmt.
MPS
RCCP
FAS
MRP
CRP
MRP outputs
Summary BOMs list all parts and their quantities required in a given product Note: structure. Unlike indented bills of materials, summary BOMs do not list level of manufacture, and they list components only once for the total quantity used.
Bill of material
Computer-generated bill of material Level 3 lists components for three subassemblies: Stator assembly Rotor assembly End bell-top
BOM for electric motorLevel 3
Map of components journey from work center to work center Operation number Operation description and standards Work centers Operation 10 Mix
(1 hour/batch)
Operation 20 Fill
(100 bottles/minute)
Blending
Ingredients
Fill line
Bottles, caps, and labels
Offsetting
Start production of D One week
Two weeks
B E
One week
Two weeks
Two weeks
E
One week
G
Three weeks One week
D 1 2 3 4 5 Time in Weeks 6 7 8
MRP
Automates BOM Improves on-time delivery; frees up time to plan Assumes infinite capacityhence, impossible schedules
Closed-Loop MRP
Refinement of MRP: provides feedback on capacity available Tradeoff: installation and training costs
MRP II
Includes financials (crosses boundaries) Makes capacity more visible Translates detailed information to financial statements Helps realign with plan
versus
Drawbacks
Bullwhip effect Doesnt account for needs of other SC partners Ignores suppliers ability
Drawbacks
Customers dont determine own orders Doesnt account for local conditions
Pull system
1. Enters order Retailers 4. Ships inventory Distributor
Push system
1. Automated sales data Retailers 4. Ships inventory Distributor 2. Factory management makes inventory 3. Ships decisions inventory Factory
2. Requests inventory
Factory
3. Ships inventory
DRP components
Forecasting
Distribution network
Distribution requirements plan Resupply needs Gross to net calculations Planned order recommendations Exception action messages Input to MPS
Resupply action plan
DRP requirements
Net Requirement
Gross Requirements
Safety Stock
PAB
Scheduled Receipts
Gross requirement is retail demand forecast Accurate lead time information required for order release dates Shortages and overstocks potentially reduced Better customer service, lower inventory costs can result from more frequent release of smaller orders
Warehouse A
1 Gross reqmts Schd receipts Proj avbl Net reqmts Plnd ord rcpts Plnd ord rlses 100 90 10 30 70 100 100 80 2 80 3
Week
4 80 70 5 80 6 90 7 90 8 90
50 50 100 100
80 20 100
10 90 100
20 80 100 100
30 70 100
100
100
Lead Time
Warehouse A
100
After having learnt the purpose and elements of Material Requirement Planning Lets now look at the concept and objectives of Capacity Requirement Planning
Capacity Management
Capacity KPIs
Too Much
Supply > Demand Layoffs, idle machines, unused storage, etc., or excess inventory
Too Little
Demand > Supply Stockouts, broken orders, or overtime, temps, work shifts, etc.
Capacity Management
Time horizons of capacity management
S&OP/production plan Resource requirements plan Rough-cut capacity plan Capacity requirements plan Long range Medium range Short range
Plan
Implement/ control
Capacity control
Short range
Capacity Management
Production activity control
S&OP
Resource planning
Plan Execute
Resources Schedule
Control
Priority Tracking Monitoring Reporting
MPS
RCCP
MRP
PAC
Manufacturing Operations
Capacity Management
Concentrate on constraints
S&OP
MPS
MRP
PAC
Keep inventory before constraint. Maintain optimum incoming rate. Improve constraint flow. Avoid constraint when possible. Reschedule (last resort).
Capacity Management
Use visual signals
S&OP
Pull inventory through with visual signals (e.g., kanban). Start production only at signal. Maintain smallest possible lot sizes. Synchronize entire chain to customer requirements.
MPS
MRP
PAC
We are now clear on the concept and objectives of CRP. Lets have a look at the concept, benefits and element of Inventory Management
Inventory Management
Inventory management KPIs
Inventory Management
Why have inventory?
1 2 3 4 5
To meet future demand To cover fluctuations in supply or demand To fill the pipeline (while other goods are in transport) To hedge against price fluctuations For economies of scale
Inventory Management
Four types of inventory
(1) Raw materials: Held to decouple, get good price, ensure supply
(2) Work-in-process: Held during idle time at plant (slow cycle times)
(3) Finished goods: Items held in readiness for purchase by end customer
Manufacturer
Distributor
Inventory Management
How you count, counts
Cycle Count
May Jun July
Count some items each day Count all items a set number of times annually Count A items more often than B or C items Timely correction of errors, no store shutdown
Aug Sep Oct Nov Dec Jan Feb Mar Apr
Periodic Count
Traditional method, requires store shutdown Annual count of all items Often done by temps Disruptive, expensive, error-prone Necessary for, e.g., retail
Inventory Management
Inventory costs
Carrying costs (holding costs): rent, depreciation, operating cost, taxes, insurance, handling, leases, labor, scrap, investment costs, pilferage, etc. Ordering costs incurred when ordering more inventory: materials and labor in processing forms; also setup costs related to preparing for production, such as cleaning, adjusting, modifying machines, etc. Other costs: backorders, lost sales, lost customers, etc.
Inventory Management
Safety stock and service levels 100% 98% 95% Customer Service
Diminishing returns
Beware of diminishing returns. Cost of safety stock + cost of stockouts: one number. Decrease safety stock need by
Frequent orders Shorter lead time More accurate forecasts.
Safety Stock
Now that we have understood the various elements of Inventory Management Lets understand what Logistics is, what are its functions and how is it different from SCM.
Logistics is
All tasks necessary to get the right goods to the right place at the right time in the right condition for the right priceglobally.
It Includes
Raw materials
S3
S2
S1
Plant
C1
C2
C3
End users
SCM is more strategic in nature, Logistics is more operations-oriented. Logistics can be considered as a part of SCM. Lets see clearly how is SCM different from Logistics
Safexper t
You
Sourcing and Procurement Manufacturing Coordination and Collaboration Integration of Supply and Demand Management
Inventory Management Inbound and Outbound Transportation Materials Handling Packaging Communication Warehousing Supply and Demand Planning Data Analysis LOGISTICS MANAGEMENT
Now that we have understood the difference between Logistics and SCM You might want to know more about the segmentation of Logistics. Lets look at these one by one
Warehousing
Labeling And Assembling
Domestic Logistics
Express Services
Transportation
Cold Chain, etc.
Warehousing
Warehousing refers to the storage of product and goods to be transported, whether inbound or outbound The warehousing segment constitutes about 35% of the total logistics industry in India
Warehousing
A very brief history of warehousing
Warehousing
Value-added warehousing Suppliers S1 Warehouses
Components
Production Plant
Warehouses
Finished goods
Customers C1
S2
Raw materials
Plant
Finished goods
C2
Warehousing activities
Warehousing
The effects of adding warehouses
Pro Customer service improves. Transportation costs decline with shorter distances to travel. Rapid delivery may improve competitive position. Decentralized system allows better service to small customers. Con Inventory costs rise with redundant functions, safety stock. Setup and overhead costs go up.
Total cost
Total cost Inventory cost Warehousing cost Transportation cost Cost of lost sales
Number of Warehouses
Warehousing
Who should own the warehouses?
Private
Structure
Firm itself owns warehouses Control; no markup; strongest market presence Inflexible budget; depreciation; illiquidity of asset
Public
Independent ownership; fee for services
Contract
Independent ownership; longer-term relationship
Benefits
Flexibility; economies of Tailored services; lower scale and lower labor costs; flexibility; access to costs more markets; stable relationship Loss of control; less market presence; markups Loss of control; less market presence; markups
Drawbacks
Warehousing
Warehousing capabilities: consolidation
Benefits
Combining inbound or outbound shipments for economies of scale to reduce logistics costs Reduced congestion at receiving dock
Warehousing
Warehousing capabilities: break-bulk
Benefits
Plant A Customer X
Break-bulk warehouse
Customer Y
Combining inbound or outbound shipments for economies of scale to reduce logistics costs Reduced handling costs (no storage)
Customer Z
Warehousing
Warehousing capabilities: cross-dock
Customer X Customer Y
Benefits
Combining inbound or outbound shipments for economies of scale to reduce logistics costs Reduced handling costs (no storage)
Company/ Plant C
Customer Z
Warehousing
Warehousing capabilities: postponement
Component supplier
Component supplier
Benefits
Component supplier
More efficient storage More accurate forecasting Less safety stock required Mass customization
Drawback
Increased costs for hiring, training, and (possibly) finishing
Warehousing
Warehousing capabilities: stockpiling
Benefits
Seasonal goods supplier
Distribution center
Efficient use of production from eliminating seasonal increase and decrease in capacity Reduced chance of seasonal stockouts
Drawback
More warehouse capacity than required for JIT delivery
Warehousing
Warehousing capabilities: mixing
Customer W
Benefits
Customer X Customer Y
Serves customers by reducing their costs for handling, storage, etc. Increases efficient use of warehouse space
ABCD
Customer Z
Warehousing
Goals and limitations of equipment and automation
Goals Add SC value through effective use of Space Labor Equipment Technology. Equipment Vehicles and conveyers Sorting and picking systems Auto storage and retrieval systems Materials handling systems Limitations May add cost without increasing value Must blend with space, labor skills, layout, etc. May require expert advice and software to select Depreciation and early obsolescence
Warehousing
Forklift trucks
Tradeoffs
+ Flexible delivery in all
directions
Warehousing
Conveyers
Type Conveyers
Tradeoffs
+ Inexpensive operation + Reduced labor costs + Efficient use of space
Warehousing
Towlines
Type Towlines
Tradeoffs
+ Efficient use of space + Can improve inventory with
scanners
Limited to straight-line delivery Expensive to automate, use in complex systems Rapid obsolescence
Warehousing
Tow tractors with trailers
Tradeoffs
+ More flexible than towlines
Warehousing
Bridge and wagon cranes
Tradeoffs
+ Can lift heavier objects than
forklift or conveyer + Efficient use of space + Automation, remote operation available (bridge)
Very expensive
Warehousing
Automated guided vehicle systems (AGVS)
Tradeoffs
+ Programmable for flexibility
without need for operator narrow aisles, reach high shelves
Warehousing
Sorting and picking systems Type
Pick-to-light systems
Benefits
+ +
Warehousing
Automated sorting devices Type
Automated sorting devices
Benefits
+ +
Reduced human time and labor for retrieval and storage Speeds up to one package per second
Warehousing
Automated storage and retrieval systems Type
Automated storage and retrieval systems (AS/RS)
Tradeoffs
+ + +
Maximum storage allowed per square foot of floor High storage and retrieval speed with few errors Reduced labor cost and human errors High cost
Warehousing
Information technology
Technology
Electronic data interchange (EDI) Bar coding Radio frequency identification (RFID) Auto ID
Function
Directs information electronically around entire SC to compatible computers Production ID information coded in bars and spaces on package; scanner reads directly into database Implanted chip with product information; can track single item anywhere, sending information through Internet to SC partners Advanced read-write incarnations of RFID; includes RFID plus voice transmitter for hands-free operation on warehouse floor
ValueValue-added Services
Packaging is a coordinated system of preparing goods for transport, warehousing, sale, and end use. It protects the goods from damage and spoilage
Labeling and Assembling Labeling is any written, electronic, or graphic communications on the packaging or on a separate but associated label. Assembling is putting the components of any product together in a form as may be required.
ValueValue-added Services
Express Services to send a package from one point to another using a special rapid-delivery service Tracking and Tracing a process of determining the and past locations (and other information) of a
current
consignment. Cold Chain can be defined as a series of inter-related facilities for maintaining ideal storage conditions for perishables from the point of origin to the point of consumption in the food supply chain These services are generally availed in combination and seldom as stand alone.
Logistics
Logistics Goals
Rapid response capability Minimum variance Minimum inventory expense Consolidated shipments High quality service Product life cycle support
Logistics Strategies
Coordinating functions Integrating the supply chain Substituting information for inventory Reducing number of partners Pooling risks
Transportation
Goals of transportation decision makers
1 Shipper Goals
Convenient schedule Low cost (for them) of shipping Limits on liability for loss, damage, etc. Good infrastructure (Who pays?)
2 Recipient Goals
On-time arrival Low cost (to them) of shipping No loss, damage, etc.
3 Carrier Goals
Convenient schedule Good revenue for service Limits on liability for loss, damage, etc.
Transportation
Goals of transportation decision makers
4 Government Goals
5 Public Goals
Stable, efficient, predictable, and Stable, efficient, predictable, and affordable passenger and commercial affordable passenger and commercial service service Infrastructure suitable for national defense uses Concerns: Ownership (public or private?), funding (taxes?) Balance between convenience, cost, environmental consequences, etc. Concerns: Ownership (public vs. private?), funding (taxes?)
Transportation
Major modes of transportation: rail
Capabilities Heavy loads (equal to water) Any load (with bulk restrictions) Low-value cargo Relatively low rates Low variable costs
Market Carries second greatest percentage of U.S. cargo Low variable costs, high fixed costs Few carriers (U.S.), mostly consolidated Intermodal options growing
Limitations Restricted destinations, little chance to expand Slow because of stops, switching (especially in EU) Rough ride
Transportation
Major modes of transportation: road
Capabilities
Small shipments; highvalue items; short to medium hauls Greatest accessibility for pickup and direct delivery Speedy delivery
Market
Low fixed costs with taxfunded infrastructure High variable costs: Wages, equipment, etc. Easy entry, many carriers available; TL, LTL, specialty Some regulatory limits on type of cargo
Tradeoffs
Labor-intensive with rising rates Intense competition with resulting bankruptcies Less hazardous than rail or water for high-value goods
Transportation
Major modes of transportation: water
Market
Tradeoffs Limited accessibility, other transport required to/from port Slow travel (trains faster but higher cost) Harmful to environment
Used in U.S. Great Lakes, rivers; EU rivers; China and SE Low-value, highdensity cargo such as Asia and elsewhere Waterways maintained coal or grain Very low per-mile cost by taxpayers and fuel-efficient Low fixed costs for ease of entry, private fleets
Transportation
Major modes of transportation: pipeline
Capabilities
Challenges
Special adaptation for crude oil, petroleum products Cargo limited to liquids, slurry No packaging required Storage and transport combined Usable 24/365 in all weather Move about same percentage U.S. cargo as water Fixed costs similar to rail; low operating cost (no driver required) New types of cargo being developed in slurry form Costly construction Limited access Political barriers at borders Vulnerable to terrorism
Transportation
Major modes of transportation: air
Capabilities
Market
Speedmay Low fixed cost, high eliminate safety stock variable cost Smooth ride for valuable and perishable cargoes or any cargo Lower packaging expense
Private business in U.S.; public elsewhere Very high delivery costs per ton/mile Competes for transoceanic carriage Tiny percentage of overall cargo market
Transportation
Transportation desirability criteria
Cost Speed Reliability Capability Accessibility Security
3 2 4 1 5
3 4 2 5
4 5 2 3
5 4 2 3 1
4 5 2 3
3 4 2 5
Transportation
Intermodal operators
Piggyback Fishyback
Trailer or container on rail flatcar Truck trailer, RR car (trainship) or container (containership) on ship or barge Air transport plus surface transit to/from terminal: used by UPS, DHL, FedEx, TNT, etc.
Benefits
Lower costs, flexibility, and efficiency, especially with use of containers on multiple modes
Birdyback
Transportation
Legal types of carriers
Type of Carrier Private
Description Shippers own fleet of vehicles for carrying own goods (and possibly some other goods). Perform bulk of shipping. Subject to most regulation. Required to serve commercial shippers.
Benefits Control of vehicles Possible crosslicensing since deregulation for backhaul loads No upkeep costs Availability, rates supported by regulations Carrier assumes risk
Drawbacks Maintenance cost Problems when business slows Core competence? Empty backhauls Most economic regulations to consider
Common
Transportation
Legal types of carriers
Type of Carrier Contract
Description Work on contract with specific clients. Not required to serve all shippers. Negotiable (not regulated) rates. Free from most federal regulation (state-licensed in U.S.). Restricted to specific marketsmostly agriculture.
Exempt
We have already discussed about Logistics and its segments. Lets understand the different types of logistic service providers
Management of the Entire Supply Chain Forwarding/ Contract Logistics One-Stop Shop Traditional Transport and Warehouse Management Own Operating of Logistics by the Producer
2PL
ASSET BASED LOGISTICS
1PL
PRODUCER
I know what are the different kinds of logistic service providersbut can you explain these in detail?
Yes, of course. Lets take up each kind of logistic service providers and understand these clearly
Safexper t
You
A First-Party Logistics Provider (1PL) is a firm or an individual that needs to have cargo, freight, goods, produce or merchandise transported from Point A to Point B consignee
The carrier who connects the consignor and the is the First-Party LSP (Logistics Service Provider)
A 1PL can be a manufacturer, trader, importer/exporter, wholesaler, retailer or distributor in the commerce field. It can also be institutions such as government department or an individual or family moving from one place to another
Shipping lines: who own, lease or charter ships Airlines: who own, lease or charter aircrafts Truck Companies: who own or lease trucks Barge Companies: who own, lease or charter vessels for carrying heavy loads through canals
Third-Party L. S. P specializes in integrating operations such as receipt of merchandise, warehousing, invoice generation, pick and pack, transportation, delivery and desired M.I.S 3PL is estimated to grow at about 30% annually
A Fourth-Party Logistics Provider (4PL) - Logistics operation that uses 3PL services on behalf of its customers rather than controlling a large network and a fleet of vehicles A 4PL is an independent, singularly accountable, non- asset based integrator who will assemble the resources, capabilities and technology of its own organization and other organizations, including 3PLs, to design, build and run comprehensive supply chain solutions for clients.
PLANT
3PL Piggyback
Electronic Supplier
4 PL Air Express
3PL Trucker
Retail Customer
PLANT
3PL Piggyback
Electronic Supplier
4 PL Air Express
3PL Trucker
Retail Customer
4PL express carrier as consultant arranges all logistics for plant and provides express airits core competency.
Reverse Logistics
Payments
Raw material supplier Component supplier
Information Flows
Plant Distributor
Material Flows
Retailer End user customer
Material flows
Payments
Credits Cash refunds Rain checks Discounts Service contract fees
Reverse Logistics
Why have a Reverse supply chain?
Aftermarket revenue Competitive edge Pressure Green revenue Conscience
Sell recovered metals, etc., from returned products, containers Woo consumers with promise of excellent customer service Comply with Green pressure from shareholders, consumers, regulators Sell into market for organic, natural, chemical-free, ecologically safe products Do the right thing
Reverse Logistics
The reverse logistics hierarchy
Reduce
Reducing resource use is considered to be the most responsible Green strategy Design products for reuse of materials and components and with easy upgrades to extend life
Reuse
Recycle
Recover Energy
Dispose of product but recover energy in the process; e.g., trash to energy plants
Responsible landfill
Last resort: Send unusable, unrecyclable materials and components to a responsible landfill
We have learnt Logistics concepts, its segments, processes, strategies, etc. Do you know?
Which is the largest logistics market in the world? What is the cost of Logistics in India as compared to other countries?
The annual logistics cost internationally varies between 9% and 20% of the GDP The US logistics market is the largest in the world and accounts for one-third of the world logistics
S.NO. COUNTRY 1. 2. 3. 4. 5. 6. US EUROPE JAPAN INDIA THAILAND CHINA ANNUAL LOGISTICS COST (% OF GDP OF COUNTRY) 9% 10% 11% 13% 16% 18%
Can you see Indias logistics cost is 13% which is more than that of US, Europe and Japan do you think we can surpass them in reducing it!
We know that the cost of logistics is high in India. Lets understand the reasons for high cost of logistics in India
Poor quality of infrastructure Inadequate service quality Domination by unorganized sector with organized sector merely being less than 10% Large portion of the employment constitutes semi-skilled or minimally educated workers Focus on Physical Distribution rather than Integrated Logistics Management
We have understood the reasons behind high cost of logistics in India Lets see the scope & bottlenecks of this industry
Role of Government
The impending introduction of a goods and service tax (GST) , aimed at creating a uniform tax regime across India irrespective of state boundaries, is expected to boost logistics and supply chain industry The Indian government has earmarked about INR 50,000 billion according to the XII Five Year plan (2012-17) against INR 25,000 billion in the XI Five year Plan (2007-12) for infrastructure investment. Around one-fourth of this investment is expected to be in roads, rail, aviation and port projects representing a sharper focus on transportation infrastructure.
Infrastructural Bottlenecks
Increasing Demands for providing one-stop solutions to different supply chain needs & for investing in Progressive Technology
We have learnt about the logistics in India Lets now look at Global Logistics practices and International Business
Shipper and seller of the cargo The exporters customer, who buys the cargo and is responsible for payment of import duties at customs Contractor responsible for getting goods from dock to dock and who arranges transportation for the exporters cargo Non-vessel common carrier that arranges transport of cargo from port to importer and contracts for or purchases space on the ocean vessel for resale or its own use Firm that consolidates shipments to load into empty vehicles for return trip from importers dock to port Has expertise to move a shipment through customs expeditiously and to ensure complete documentation
An export arrives
with help from many friends
Exporter
Domestic carrier
Consolidator Government
Bank
F Terms
E terms plus seller arranges and pays for export documentation and delivers goods, ready for export, to specified point or port in sellers country.
C Terms
F terms plus seller arranges and pays for international transport services to point or port in buyers country.
D Terms
C terms plus seller arranges and pays for delivery and documentation services inside buyers country. DAF named port along Netherlands-German border Invoice: USD 13,750.00 DDP buyers named facility, Frankfurt Invoice: USD 15,500.00
CPT Maersk Terminal, FOB Chessie System Intermodal Yard, Chicago, Rotterdam IL Invoice: USD 10,300.00 Ex Works plant, factory Glen Burnie, MD Invoice: USD 10,000.00 FOB Med Shipping Terminal, Port of Baltimore: Invoice: USD 10,300.00 Invoice: USD 12,800.00 CIF Maersk (seller also pays insurance) Maersk Terminal Invoice: USD 13,000.00
Exporter
Importer
Bank 1 pays Bank 2 (after cargo arrives) Bank 2 asks Bank 1 for payment
Topic Review
Demand planning: overview Supply chain dynamics Forecasting Types of collaboration Role of marketing in demand planning Collaborative product design for the supply chain Sales and operations planning (S&OP) Master production scheduling Material requirements planning
Topic Review
Distribution requirements planning Capacity management Inventory Management Transportation Warehousing 3PL and 4PL Reverse logistics Global logistics and International
business