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Improving the Procurement Process of a Locomotive Manufacturer: A Quantitative Approach Rajnish Kumar PhD Scholar Enroll No 301748 Supervisor: Prof S.K. Sharma Dept of Mechanical Engineering, IIT (BHU), Varanasi 1

PhD Presentation Rajnish Kumar 2014

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Page 1: PhD Presentation Rajnish Kumar 2014

Improving the Procurement Process of

a Locomotive Manufacturer:

A Quantitative Approach

Rajnish KumarPhD Scholar Enroll No 301748

Supervisor: Prof S.K. SharmaDept of Mechanical Engineering, IIT (BHU), Varanasi

1

Page 2: PhD Presentation Rajnish Kumar 2014

IntroductionOverview

The locomotive manufacturer is a production Unit under Ministry of Railways.

Manufactures Diesel Locomotives, mainly of two types ALCO (being phased out) and

EMD (Now called HHP, high Horse Power Locos).

Total Budget for 2011-12 – Rs 3265 crore

TARGET – 275 locos, out of which 215 are HHP type.

2

Page 3: PhD Presentation Rajnish Kumar 2014

Production Trend

Due to Supply Chain constraints, the unit was compelled to reduce

Railway Board’s target from 215 HHP locos to 185.

3

2239

5980

110

150

190126

147

163

177

148

117

69

148

186

222

257 258267

259

0

50

100

150

200

250

300

2005-06 2006-07 2007-08 2008-09 2009-10 2010-11 2011-12

No

. o

f L

oco

mo

tiv

es

HHP ALCO

Page 4: PhD Presentation Rajnish Kumar 2014

Scope for improvement

• The tender process for all items is

common.

• Scientific classification of items is absent

• Even very standard items get out of stock

• Vendor/supplier evaluation and

development methods are subjective

4

Page 5: PhD Presentation Rajnish Kumar 2014

Scope for improvement…2

• Without passing on the benefit of long

term contracts, in practice same vendors

remain in system for years

• Well trained technical staff involved with

supply coordination

• High level of inventory- about 3.5 months

5

Page 6: PhD Presentation Rajnish Kumar 2014

ObjectiveThree parts of work

1. Suggest scientific classification of items using a quantitative model, and suggest types of contract

2. Estimate Optimal number of suppliers

3. Formulate methodology of supplier evaluation for both existing and new suppliers

6

Page 7: PhD Presentation Rajnish Kumar 2014

Approach and Methodology

Literature review has been done in supply chain

research and the focus is on:

1. Strategic sourcing – Kraljic model has been taken as

foundation of analysis

2. Optimal number of suppliers – using the probability

for supply chain disruption due to global or local

event and quantity discount

3. Supplier evaluation and rating methods – Taguchi

Loss Function, Analytic Hierarchy Process (AHP)

and Technique for Order Preference by Similarity to

Ideal Solution (TOPSIS) techniques have been used

7

Page 8: PhD Presentation Rajnish Kumar 2014

Salient features of Procurement system

• Production Plan is received 2 years in advance, but ordering is done on a yearly basis assuming lead time to be about 6-12 months

• All types of material/items are procured in the same manner

• The purchase organization is headed by a CONTROLLER OF STORES

• Supplier/Vendor assessment, approval and development is with DESIGN Department under Chief Mechanical Engineer.

8

Page 9: PhD Presentation Rajnish Kumar 2014

Salient features of Procurement system…..

• There is a Material Control Organization (MCO) whose function is to generate indents

• MCO also follows up material availability once Purchase Orders are placed.

• MCO is under administrative control of Controller of Stores(COS).

• The Technical Evaluation of offers in Tenders is done by DESIGN department for most of Loco items.

9

Page 10: PhD Presentation Rajnish Kumar 2014

Salient features of Procurement system…..

Unscientific system of tendering

• In the same class of items, for each item there are separate vendors

and tender is done for all, increasing work volume without any value

addition to supply chain.

Item class Total types No. of Vendors

Gaskets 99 8

Angles 46 9

Bracket and

bracket assembly27 16

Bush and bushing 25 15

10

Note: The manufacturer has started work on this already

Page 11: PhD Presentation Rajnish Kumar 2014

Salient features of Procurement system…..

Issues with number of approved Suppliers

• It can be seen that number of approved suppliers is not adequate and thus ordering has to be done on unapproved/new suppliers

Part-I Vendors as per Composite Vendor Directory DLW

Type of Product Number of Part-I Vendors Total

ITEMS NIL 1 2 > 2

HHP 191 1102 780 185 2258

ALCO (OLD getting Phased out) 335 610 375 139 1459

HARDWARE33 422 234 153 842

RAW MATERIAL59 52 20 0 131

TOTAL618 2186 1409 477 4690

% of TOTAL

ITEMS 13% 47% 30% 10%

What should be the optimal size of supplier base?11

Page 12: PhD Presentation Rajnish Kumar 2014

The decision variables– Disruptions in supply

– Failure Rate

– Price

– Complexity/Technological intensiveness

Seminal Paper

Kraljic, P., (1983), Purchasing must become supply management,

Harvard Business Review, 16(5), 109-117

12

PART I

Classification of material/items

Page 13: PhD Presentation Rajnish Kumar 2014

13

CATEGORIES

I Strategic

Complex

Cost

II Development

Complex

Subject to supply disruptions

III Bottleneck

Failure Rate

Subject to supply disruptions

IV Normal

Cost

Failure Rate

Classification of material/items

Page 14: PhD Presentation Rajnish Kumar 2014

Definition of Variables

Factor Code Definition

Disruptions in

supply

S Number of loco days lost compared to total

days lost in the Decision Period by all

suppliers for the subject item,

expressed as %

Failure Rate F % failed in the total supply of the item by

all suppliers

Price P Average price of item expressed as % of

highest priced.

Complexity/

Technological

intensiveness

C Scale 1 - 100

These values will be plotted on a graph

14

Page 15: PhD Presentation Rajnish Kumar 2014

Model for classificationThe C, S, F and P

values are plotted

and polygon is

formed.

The coordinates of

the centroid would

define the category

of the item.

For example in this

case the item is a

bottleneck item

15

Page 16: PhD Presentation Rajnish Kumar 2014

Calculation of Region

For the polygon that is

formed by the four

variables, the points

are

Using these values in the

equation for calculation of

centroid of polygon, we get

x0

y3

x2

y1

Area of

Polygon

Note: These are absolute values16

Page 17: PhD Presentation Rajnish Kumar 2014

P, xo C, y1 S, x2 F, y3

ITEM RATE

Total loss

in Loco

days(3 years)

Price ComplexitySupply

Disruption

Failure

Rate A Cx CyCategory

AC-AC

Traction

System

25836115 2211 100 95 7.49 3 5266.99 30.84 30.67 I

TCC 19061099 1035 74 90 3.51 6 3709.58 23.42 28.00 IAlternator 7500000 247 29 100 0.84 10 1642.62 9.40 30.00 ITraction

Motor2671481 4390 10 95 14.87 15 1386.60 -1.51 26.67 II

Draft Gear 153618 222 1 80 0.75 8 59.25 -0.05 24.00 IIUnion

Elbow153618 33 1 10 0.11 5 5.30 0.16 1.67 I

Master

Controller 126575 885 0 90 3.00 5 165.67 -0.84 28.33 II

Elbow 20847 168 0 10 0.57 15 8.12 -0.16 -1.67 IIITM Air

Duct Boot20847 48 0 10 0.16 20 3.65 -0.03 -3.33 III

L O

Manifold15447 200 10 10 0.68 14 128.13 3.11 -1.33 IV

17

Some Examples for Classification of item

Page 18: PhD Presentation Rajnish Kumar 2014

Part IIOptimal number of Suppliers

• Rationalization of supplier base is the first step towards developing long term relationships. Rationalization and reduction are not the same things.

• It is a tight rope walk, as small supply base gives rise to risk of supply disruptions.

• A large supply base raises the fixed costs and the ordered quantity per supplier reduces due to which suppliers may not extend price benefit to manufacturer.

18

Page 19: PhD Presentation Rajnish Kumar 2014

SEMINAL PAPER: Berger, P. D., Gerstenfeld, A., and Zeng A.Z. (2004), How Many

Suppliers are best? A Decision-Analysis approach, Omega: The International

Journal of Management Science, 32(1), 9-15

Pg is the probability of Global event

Si is the probability of Local event for supplier i

The model assumes,

For i≠j, Si and Sj are independent,

And Pg , Si are independent events

The probability that supplies from supplier i are disrupted, failed (f) is,

Model for estimating, n*

optimal number of suppliers

19

Page 20: PhD Presentation Rajnish Kumar 2014

There are certain conditions:

•The number of suppliers is chosen from i= 1 to n.

•There are two conditions, all suppliers fail, or some fail.

•If all suppliers fail, there is a loss to company denoted by Lt

•The cost of operating a supplier, i is C(i), i=1,2,….,n.

•The Expected Total Cost (E) from the system when only one

supplier is used

Derivation of formula

20

•The Expected Total Cost (E) from the system when n suppliers are there,

Page 21: PhD Presentation Rajnish Kumar 2014

Derivation of formula, MODEL-B by Berger

For determining the optimal size of suppliers, we have to

compare cost of operating n+1 suppliers to n suppliers.

Consider that the cost of maintaining a supplier is a linear

function of n,

Then C(n) is given by the following expression:

C(n) = u + v(n), u is fixed cost and v is variable cost

Using these functions, the formula arrived at is,

21

Page 22: PhD Presentation Rajnish Kumar 2014

Derivation of formula – adding QUANTITY DISCOUNT to

Model-B

22

Where,

A is the cost of item

θ is a parameter for highest discount and is estimated as 0.05

for present study

λ is a variable for rate of decrease in discount

n is the number of suppliers

Page 23: PhD Presentation Rajnish Kumar 2014

Derivation of formula – FINAL

23

The procedure is to increase, n till E (n+1)- E

(n) >0, which means that it is costlier to operate

(n+1) suppliers than n. The number n thus

obtained will be the optimal number of

suppliers n*.

Page 24: PhD Presentation Rajnish Kumar 2014

Application to OEM’s case

24

v θ λ Pg S Lt

2000 0.05 0.4 0.05 0.1 300000

Result

A, cost of item in Rs n*, optimal number of suppliers

5000 3

10000 3

50000 3

100000 2

200000 2

500000 2

1000000 2

5000000 1

10000000 1

25000000 1

Page 25: PhD Presentation Rajnish Kumar 2014

Sensitivity Analysis

25

In order to authenticate the model the sensitivity

test must be carried out. This is carried out to

notice whether the model is following natural rules

or not.

There are two situations:

• Parameters common to Model-B and the

present model: compare n*

• Parameters unique to the present model: no

comparison

Page 26: PhD Presentation Rajnish Kumar 2014

0

1

2

3

4

0 0.05 0.1 0.15

Global probability of failure

n*

n*(Berger)

0

1

2

3

4

5

0.00 0.10 0.20 0.30 0.40

Probability of supplier's failure

n*

n*(Berger)

0

1

2

3

4

5

0 10000 20000 30000 40000 50000 60000

Loss due to supply disruption

Hundreds

n*

n*(Berger)

0

1

2

3

4

0 20000 40000 60000

Cost of maintaining a supplier

n*

n*(Berger)

Sensitivity AnalysisCompare present model and model-B

Page 27: PhD Presentation Rajnish Kumar 2014

0

1

2

3

4

0 5000 10000 15000 20000 25000 30000

Price of item

Thousands

n*

n*

0

1

2

3

4

0 0.02 0.04 0.06 0.08

% discount offered by supplier

n*

n*

0

1

2

3

4

0 0.5 1 1.5

Rate of decrease in % discount

n*

n*

Sensitivity AnalysisOnly this model

Page 28: PhD Presentation Rajnish Kumar 2014

• Based on past research and analysis of systems at 20 major manufacturers, four salient criteria have been found important in supplier evaluation, namely,

– QUALITY

– ON-TIME DELIVERY

– PRICE

– SERVICE

• Therefore, in this study, these four valuable criteria are incorporated into the Taguchi loss function, then combined into a total loss under a weighted consideration via an Analytic Hierarchy Process (AHP).

• The TOPSIS (Technique for Order Preference by Similarity to IdealSolution) method which is popular in literature has been employed to determine the final ranking of the suppliers.

28

Part IIISupplier Selection using Taguchi Loss Function and Multi Criteria Decision Making techniques

Page 29: PhD Presentation Rajnish Kumar 2014

Taguchi Loss Function

The two functions used

It is preferred to maximize the result, and

the ideal target value is infinity

HIGHER-IS-BETTER

The ideal target value is defined as

zero

SMALLER-IS-BETTER

29

L (y) = k /(y)2 L (y) = k (y)2

According to Taguchi, if a characteristic measurement is the same as the

target value, the loss is zero. if it is on lower or upper specification limit, loss is

100%.

Page 30: PhD Presentation Rajnish Kumar 2014

Decision Variables for selecting a supplier

Criteria Target Value RangeSpecification

limit

Quality 0% 0-5% 5% rejectionLower the

better

Delivery 0 0-15 15 daysLower the

better

Price Lowest 0-10% 10% higherLower the

better

Service 100% 100%-50% 50% lowerHigher

the better

NOTE: The loss is estimated by assuming that if 5% items are rejected there is

100% loss in Quality criteria, or

If supply is delayed by 15 days there is 100% loss in Delivery criteria etc.

30

Page 31: PhD Presentation Rajnish Kumar 2014

Calculation of loss coefficient

CriteriaTaguchi

Function

Specification

limit

Loss

(assuming 100% loss at

spec limit)

Value of k

Quality ky2 5% rejection 100=k x (0.05)2 40000

Delivery ky2 15 days 100=k x (15)2 0.4444

Price ky2 10% higher 100=k x (0.10)2 10000

Service k/y2 50% lower 100=k / (0.50)2 25

Using these values of k, TAGUCHI LOSS of each supplier is computed.

31

Page 32: PhD Presentation Rajnish Kumar 2014

Outputs of Taguchi Loss for suppliers

Characteristics of Suppliers

Supplier Quality

% rejection

Delivery

delay in

days

Price

compared

to lowest

Service

level

judgment

A 3% 5 0% 85%

B 3% 6 6.50% 75%

C 2% 7 8.40% 80%

D 4% 2 4.20% 65%

These values in the matrix

will be used to calculate

the Taguchi Loss for each

Supplier, criteria wise,

using the value of loss

coefficient calculated

before.

But before this the

relative importance of

each criteria will be

found using AHP.

32

Page 33: PhD Presentation Rajnish Kumar 2014

Using AHP to find relative

importance of criteria• AHP – Analytic Hierarchy

Process is a well

established process to

assist the decision maker’s

judgment concerning the

relative importance of

criteria. It was developed

by Saaty in 1970s.

• There is a scale 1 to 9

lowest to highest relative

importance

Criteria compared with

Qu

ali

ty

De

live

ry

Pri

ce

Se

rvic

e

Cri

teria

to b

e com

pare

d

Quality 1 3 7 9

Delivery 1/3 1 3 5

Price 1/7 1/3 1 1/3

Service 1/9 1/5 3 1

SUM of

Column

Values1.59 4.53 14.00 15.33

33

Page 34: PhD Presentation Rajnish Kumar 2014

Normalization of Matrix and calculation of weights

• CI is the Consistency Index = (λ(max) -n)/n-1

• CR is the Consistency Ratio which should be less than 10% and,

• CR = CI/RI, RI is the Random Index which is a standard table depending on n, number of

criteria

Normalized MatrixNormalized

Principal Eigen

vector

Quality 0.63 0.66176 0.5 0.58696 62%

Delivery 0.21 0.22059 0.21429 0.32609 22%

Price 0.09 0.07353 0.07143 0.02174 8%

Service 0.07 0.04412 0.21429 0.06522 8%

λ 0.9896 1.0039 1.1161 1.1563 4.266Principal Eigen value,

λ(max)

n, number

of criteria4 CI 0.089

CR 9.8% Consistency

34

n 1 2 3 4 5 6 7 8 9 10

RI 0 0 0.58 0.9 1.12 1.24 1.32 1.41 1.45 1.49

Page 35: PhD Presentation Rajnish Kumar 2014

Integrated model for Supplier Ranking

Taguchi loss function provides the loss to system by individual supplier

AHP provides the pair wise comparison of four criteria.

Weightage of each criterion

Quality – 62%, Delivery – 22%, Price – 8% and Service – 8%.

For final ranking, method called TOPSIS is used.

35

Page 36: PhD Presentation Rajnish Kumar 2014

Integrated model for Supplier Ranking

The TOPSIS method was introduced by Hwang and Yoon,

1981.

Behzadian et al., 2012 have found that it has been applied

to many applications ranging from manufacturing to

purchasing, health, safety, energy, human resource

management, chemical engineering, water resources

management and other areas.

The method finds the solution closest to ideal and farthest

from the worst scenario. It is simple and easy to use.

36

Page 37: PhD Presentation Rajnish Kumar 2014

TOPSIS(Technique for Order Preference by Similarity to Ideal Solution)

TOPSIS is based on the

concept that the chosen

alternative should have the

shortest geometric distance

from the positive ideal

solution and the longest

geometric distance from the

negative ideal solution

37

Distance to ideal and anti-ideal point

Page 38: PhD Presentation Rajnish Kumar 2014

TOPSISSteps

38

The best satisfied alternative can now be decided according to the rank order of alternatives with relative closeness. Closest to 1 is best.

Step 6 : Calculate the relative closeness to the ideal solution

Step 5 : Calculate the separation measures for each alternative from the ideal solution and the negative-ideal solution

Step 4 : Determine Positive Ideal and Negative Ideal solutions

Step 3 : The weighted normalized decision matrix is now constructed.

Step 2 : Now the normalized decision matrix is constructed.

Step 1 : The decision matrix is constructed with m alternatives evaluated in terms of ncriteria.

Page 39: PhD Presentation Rajnish Kumar 2014

Application of TOPSIS

• Taguchi Loss by each supplier is estimated

39

Quality

Q

Delivery

D

Price

P

Service

S

Value of

Taguchi

constant, k

k= 40000 k=0.4444 k=10000 k=25

Loss k×(value)2 k×(value)2 k×(value)2 k/(value)2

Supplier Taguchi Loss Taguchi Loss Taguchi Loss Taguchi Loss

A 36 11.11 0.00 34.60

B 36 16.00 42.25 44.44

C 16 21.78 70.56 39.06

D 64 1.78 17.64 59.17

Page 40: PhD Presentation Rajnish Kumar 2014

Application of TOPSIS

After a certain number of steps, the Weighted normalized decision

matrix is created.

The positive ideal (lowest loss) and negative ideal (highest loss)

are marked in this matrix

40

Q D P S

Weights→

Supplier↓ 0.62 0.22 0.08 0.08

A 0.2678 0.0835 0 0.0306

B 0.2678 0.1202 0.0402 0.0393

C 0.1190 0.1637 0.0671 0.0345

D 0.4762 0.0134 0.0168 0.0523

Positive

Ideal

Negative

Ideal

wrv jijij

rij = normalized element

vij= weighted element

w= weight

Page 41: PhD Presentation Rajnish Kumar 2014

41

v- Negative Ideal

v* Positive Ideal

Separation measure for Negative ideal solution

Separation measure for Positive ideal solution

Separation measure of the values in each cell of weighted normalized matrix is calculated

(column wise) and summated in last column for finding the supplier’s total separation

(v - vi*)

2 Q D P S sum

𝑆𝑖∗ = 𝑣𝑖𝑗 − 𝑣𝑗

∗ 2

𝑚

𝑗=1

A 0.02214 0.00492 0.00000 0.00000 0.02706 0.16450

B 0.02214 0.01142 0.00161 0.00008 0.03525 0.18776

C 0.00000 0.02259 0.00450 0.00002 0.02711 0.16465

D 0.12754 0.00000 0.00028 0.00047 0.12830 0.35818

(vi- - v)

2 Q D P S sum

𝑆𝑖− = 𝑣𝑖𝑗 − 𝑣𝑗

− 2

𝑚

𝑗=1

A 0.04340 0.00643 0.00450 0.00047 0.05480 0.23410

B 0.04340 0.00189 0.00072 0.00017 0.04618 0.21490

C 0.12754 0.00000 0.00000 0.00032 0.12786 0.35757

D 0.00000 0.02259 0.00253 0.00000 0.02512 0.15851

Page 42: PhD Presentation Rajnish Kumar 2014

42

Ci* Ranking

A 0.587315 2

B 0.5337 3

C 0.68471 1

D 0.306774 4

The final step is estimation of Relative Closeness to Ideal, Ci* for each

supplier, ranking depends on closeness of this value to 1.

The lesser the separation measure from positive ideal, the better

The table depicts the value of Ci* and ranking of suppliers.

Final ranking

Page 43: PhD Presentation Rajnish Kumar 2014

Assessment of New Supplier

Capability factors Code

Quality systems of the supplier Q

Financial capability of the supplier F

Production facilities and capacity P

Business volume/amount of past business V

Technological capability/R&D capability T

Supplier’s proximity/geographic location G43

Page 44: PhD Presentation Rajnish Kumar 2014

AHP MatrixRelative Importance of Capability Factors

Q F P V T G

Q 1 3 5 6 8 9

F 1/3 1 2 3 6 7

P 1/5 1/2 1 3 4 5

V 1/6 1/3 1/3 1 3 5

T 1/8 1/6 1/4 1/3 1 5

G 1/9 1/7 1/5 1/5 1/5 1

sum

(col)

1.936 5.143 8.783 13.53 22.2 32

Quality systems of

the supplier Q

Financial capability of

the supplier F

Production facilities

and capacity P

Business

volume/amount of

past business

V

Technological

capability/R&D

capability

T

Supplier’s

proximity/geographic

location

G

44

Page 45: PhD Presentation Rajnish Kumar 2014

Estimation of Relative Importance

Normalization of Matrix

Q F P V T G

REL

IMP

Q 0.516 0.583 0.56926 0.443 0.36 0.281 51%

F 0.172 0.194 0.2277 0.222 0.27 0.219 19%

P 0.103 0.097 0.11385 0.222 0.18 0.156 12%

V 0.086 0.065 0.03795 0.074 0.135 0.156 8%

T 0.065 0.032 0.02846 0.025 0.045 0.156 5%

G 0.057 0.028 0.02277 0.015 0.009 0.031 4%

λ0.991 0.999 1.04679 1.092 1.187 1.294 6.610

principal

Eigenvalue

n 6 CI 0.122

CR 9.8% Consistency

45

Quality systems

of the supplier Q

Financial

capability of the

supplier

F

Production

facilities and

capacity

P

Business

volume/amount of

past business

V

Technological

capability/R&D

capability

T

Supplier’s

proximity/geograp

hic location

G

RI = 1.24 for n=6

Page 46: PhD Presentation Rajnish Kumar 2014

Final Score sheet of new supplier

46

• The score sheet assigns 10 marks to each criterion. After the tabulation of

these scores, the following Table will be used to calculate the weighted

score of the supplier, and then according to the need suppliers may be

selected for inclusion into the purchase process.

Criterion Q F P V T G Total

weighted

scoreWeight 0.51 0.19 0.12 0.08 0.05 0.04

Supplier Score Score Score Score Score Score

A

B

C

Page 47: PhD Presentation Rajnish Kumar 2014

Recommendations

Strategic Sourcing• For each of the FOUR defined class of items a different procurement method

47

Strategic

Items

Incentive to supplier by having 3 year contracts and long

term i.e. 10 year commitment. Assured business is the

key.

Development

Items

Request for Proposal must be floated, globally and

locally.

After RFP is floated and list of potential suppliers is

received, a development tender will be floated to get the

exact price and delivery schedule.

Bottleneck

Items

Limited Tendering to approved suppliers, and the goal

should be developing them to enter into long term

agreements. For such items, supplier training and

motivation is must.

Normal Items Limited tenders to approved suppliers. This class of

suppliers should be graduated to long term relationships.

Page 48: PhD Presentation Rajnish Kumar 2014

There should be the following classes of suppliers:

• Approved – The first 3 of the ranked suppliers from past performance record. They should have supplied atleast 10% of the net procured quantity for the period under consideration.

• Enlisted – Under active consideration, especially if it is found that 3 suppliers cannot meet the demand or one of the suppliers is degraded in ranking.

• Potential suppliers – Those who have supplied in past but not ranked due to less than 10% of net procured quantity for the period under consideration.

Recommendations

48

Page 49: PhD Presentation Rajnish Kumar 2014

Optimal sizing of supplier base

• There is an unscientific distribution of number of suppliers for various groups of items at OEM. In many cases for same group of items they are 10 or more suppliers, each approved only for a particular item. For each class only 3 suppliers.

Incidentally, work has already started on this issue

Institutional arrangement for Supplier Development

• The Material Control Organization (MCO) at OEM is having requisite manpower and technical expertise to carry out this work. At present they are doing non-technical function of chasing the suppliers.

This recommendation has found acceptance and MCO is being redesigned.

Recommendations

49

Page 50: PhD Presentation Rajnish Kumar 2014

Benefits estimated

OPTIMIZING THE SUPPLIER BASE will reduce the cost of items by 2-5% as due to increased volumes, the suppliers will reduce the price.

By focusing on supplier issues, the POTENTIAL LOSS due to supply disruptions can be reduced, which will mean reduction in financial loss due to non availability of loco.

A loco has earning potential of Rs 3.0 lakh per day.

50

Page 51: PhD Presentation Rajnish Kumar 2014

Benefits estimated…2

SAVING MANPOWER- THE COSTLIEST ASSET

More than 100 trained technical personnel are actively involved in purchase order execution. Much of this work is routine and can be made redundant by streamlining the process. This manpower can be effectively utilized elsewhere where there is no alternative to technical work.

REDUCTION IN INVENTORY by 2 months will mean a financial gain of Rs 40-70 crore annually by way of reduction in loss due to interest on capital.

51

Page 52: PhD Presentation Rajnish Kumar 2014

Contribution of Work

A. Quantitative model for classification of items to decide

on sourcing strategy – Four Categories defined.

B. Estimation of optimal number of suppliers considering

the probability of Global and Local event, Quantity

discounts.

C. Quantitative model for supplier evaluation for enlisting

on approved list.

D. Scientific system for assessment of new suppliers’

capability based on 6 attributes. (Perceived Fairness)

E. Procedure for enlisting of supplier in Supplier/Vendor

Directory.

52

Page 53: PhD Presentation Rajnish Kumar 2014

Observations

• There is a wide gap in research and

practice in the field of supplier selection.

• It is important to formulate practicable,

simple models which can be understood

by all stakeholders in the system.

53

Page 54: PhD Presentation Rajnish Kumar 2014

Seminal Papers/References

About 96 research papers were consulted

And supplier evaluation systems of 20 companies analyzed.

Seminal Papers

• Chai, J., Liu, J.N.K., Ngai, E.W.T. (2013), Application of decision-making techniques in

supplier selection: A systematic review of literature, Expert Systems with Applications: An

International Journal, Volume 40 Issue 10, 3872-3885

• Gelderman, C. J., Van Weele, A. J. (2005), Purchasing Portfolio Models: A Critique and

Update, Journal of Supply Chain Management, 41, 19–28

• Ho, W., Xu, X., Dey, P. K. (2010), Multi-criteria decision making approaches for supplier

evaluation and selection: A literature review. European Journal of Operational Research,

202(1), 16–24

• Kraljic, P., (1983), Purchasing must become supply management, Harvard Business Review,

16(5), 109-117

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Page 55: PhD Presentation Rajnish Kumar 2014

Seminal Papers/References

• Liao, C., Kao, H., (2010), Supplier selection model using Taguchi loss function, analytical

hierarchy process and multi-choice goal programming, Computers and Industrial

Engineering, Volume 58, Issue 4, 571-577

• Sarkar, A., Mohapatra P.K.J., (2009), Determining the optimal size of supply base with the

consideration of risks of supply disruptions, International Journal of Production Economics,

Volume 119, Issue 1, 122-135

• Berger, P. D., Gerstenfeld, A., and Zeng A.Z. (2004), How Many Suppliers are best? A

Decision-Analysis approach, Omega: The International Journal of Management Science,

32(1), 9-15

• Taguchi, G., Chowdhury S., Wu, Y., (2004), Taguchi's Quality Engineering Handbook, Wiley,

ISBN: 978-0-471-41334-9, Hardcover

• Behzadian, M., Khanmohammadi O. S., Yazdani, M., and Ignatius, J. (2012), A state-of the-

art survey of TOPSIS applications, Expert Systems with Applications, 39(17), 13051-13069

• Saaty, T. L. (1990), How to make a decision: the analytic hierarchy process, European journal

of operational research, 48(1), 9-26.

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Research Papers

• ACCEPTED PAPER

– “Classification of items and purchasing strategy using modified Kraljic matrix – A

case study of Locomotive Manufacturer in India”, International Conference on

Agile Manufacturing, IIT(BHU), Varanasi, December 16-19,2012, co-authored

with Prof S.K.Sharma

• COMMUNICATED PAPERs

– “Applying modified Berger's model considering quantity discount to estimate the

optimal number of suppliers for a Locomotive manufacturer” in Annals of

Operations Research, Springer, co-authored with Prof S.K.Sharma

– “Supplier Selection Criteria and Methodology: Practice vs. Research” in

International Journal of Logistics Management, EMERALD co-authored with Prof

S.K.Sharma

• Paper under process

– “Integrated approach for Supplier Selection using Taguchi Loss Function, AHP

and TOPSIS” co-authored with Prof S.K.Sharma

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Thank you

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