Supply Chain1

Embed Size (px)

Citation preview

  • 8/8/2019 Supply Chain1

    1/34

    9/22/20

    SUPPLY CHAIN MANAGEMENT

    DR. V.K. GUPTA

    SUPPLY CHAIN MANAGEMENT

    Supply Chain is a sequence of suppliers, warehouses, operations andretail outlets.Material and information flow both up and down thesupp y c a n.

    Supply Chain Management is the integration of all activities associatedwith the flow and transfer of goods from raw materials stage throughto the end user, as well as the associated information flow by improvedsupply chain relationship, to achieve a sustainable competitiveadvantage.

    Supplier Storage Mfg. Storage Distributor Retailer Customer

    Supplier

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    2/34

    9/22/20

    Raw Materials

    Seamless

    Supply chain

    Material flow channel

    Order flow channel

    End Customer

    Seamless supply chain

    RawMaterials

    Primary

    TRADITIONAL LOGISTICS SUPPLY

    Information

    Manufacturing

    Secondary

    Manufacturing

    Material Flow Order Flow

    Material/

    productRetail Outlet

    Customer

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    3/34

    9/22/20

    INTEGRATED SUPPLY CHAIN MODEL

    Customer Product and

    material flowRetailers

    Distribution Centres Information flow

    Assembly / Mfg. SBU

    2nd Tier Supplier 2nd Tier Supplier 2nd Tier Supplier

    Corporate

    THREE TIER PHILOSOPHY

    APPLIED TO LOGISTICS

    CONCEPTUAL Logistics STRATEGY

    Strategy

    Material and Product Flow

    FUNCTIONAL SUPPLY CHAIN

    INVENTORY TRANSPOR STORAGE, LOGISTIC SECONDARY

    -TATION HANDLING, SUPPORT LOGISTICS

    PACKING SERVICE

    SUBJECT OPERATIONAL ELEMENTTRANSAC OPERATIONAL

    -TIONAL LOGISTICS

    NITYA KARMAKAR

  • 8/8/2019 Supply Chain1

    4/34

    9/22/20

    Raw Materials

    Primary Marketing and

    Manufacturing Sales

    Assembly CUSTOMER

    Distribution Retail

    LogisticsMaterial Flow Information

    Flow

    Logistics Supply Chain ModelNITYA KARMAKAR

    STRATEGIC LOGISTICS MANAGEMENT

    Vendor Mana ed Inventor - As a vendor ets com letevisibility of stock position with the manufacturer andworks on synchronized schedules, inventory holding withmanufacturer is greatly reduced. This is successfullypracticed in retail industry.

    Distribution Network Optimization - Determining thebest location for facility, setting proper system

    reduce inventory carrying and transportation costs. Usingthese methods, IBM saved 15-20% in transport cost and15% reduction in inventory.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    5/34

    9/22/20

    Shipment consolidation and cross docking - Hub andspoke structure is used to effectively utilize all resources -Courier Service - use of real time information systemimproved fleet efficiency.

    -as adding product labels, hanging clothes on hanger etccarried out at distribution centers.

    Category Management - Handling a different customersegments through teams responsible for strategy, operationand performance.

    Channel partnership - Popular in apparel industry. Co.have formed channel partner with discount stores /distributors. This allow manufacturer to manage inventory

    levels based on data from POS and replenishing.

    Dr.V.K.Gupta

    THE GENERIC VALUE CHAIN

    MARGIN

    Infrastructure

    Support Human Resource Management

    activities Corporate communication

    Product / technology development

    Procurement

    Inbound Production Outbound Marketing Service

    logistics Operations logistics & sales

    Primary Activities MARGIN

    Production interrelationship Market interrelationship

  • 8/8/2019 Supply Chain1

    6/34

    9/22/20

    Stage 1Financial IntegrationAutomation of routine functions

    Applications such as payroll

    Stage 2Cross Functional Integration

    Focus ResultCost reduction Competition

    Increased human based on price

    roductivitFunctional coordinationMRP II - coordination ofmaterial management

    Stage 3Firm wide integrationReal time information flowBusiness transformation and processredesign

    ,

    efficiency

    Focus

    Increased

    Future

    Prime focus-

    Stage 4Decision making toolSupplier customer integrationAgilityEDI, Intranet

    profitability,

    market

    share

    service,

    Innovation

    IT Evolution - Focus and Results

    Dr.V.K.Gupta

    REDISCOVERY OF LOGISTICS - POST 1980

    Proliferation of product lines

    Balance of Power in the channel shifted from

    manufacturing to trade

    Value added by manufacturer declined as cost of materials

    and distribution increased

    Many companies relocated their facilities on a global basis Low cost, high volume information processing and

    transmission revolutionized logistics control systems

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    7/34

    9/22/20

    DEVELOPMENT OF MARKETING CONCEPT

    1950/60s

    Product ( Technology Impact )

    1960 / 70s

    Promotion ( Promotional parity )

    s

    Place ( Availability )

    1980 / 90s

    Dr.V.K.Gupta

    TOTAL UTILITY CONCEPT

    Primar Process

    Production Functional Utility

    Marketing Possession utility

    Logistics Place / Time utility

    , , , ,Resources

    Training, Budgeting, Maintenance

    Secondary Process

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    8/34

  • 8/8/2019 Supply Chain1

    9/34

    9/22/20

    ELEMENTS OF LOGISTICS

    1. Inventory2. Transportation

    Air

    4. LogisticsClearing

    Forwarding

    Road

    Sea

    Pipe

    3. Storage, Handling, Packaging

    Bulk liquid terminal

    Bulk dry terminal

    Silo

    Warehouse

    p s agent

    Surveyors

    Insurance

    Consultants

    Infrastructure

    5. Secondary logistics

    Travel service

    Open store

    Port

    Depot

    Distribution center

    Drumming

    Bagging

    Service transport

    Courier service

    Dr.V.K.Gupta

    ISSUES IN SUPPLY CHAIN MANAGEMENT

    1. INFORMATION SYSTEMS AND SUPPLY CHAINMANAGEMENT

    Centralized coordination of information flows.

    Total logistics management

    Order change notices that trigger a cascading series modifications toproduction schedules, logistics plans, warehouse operations

    Global visibility into transportation resources across business units andnational boundaries

    Global inventory management - ability to locate and track movement ofevery item

    o a sourc ng - conso at on o purc as ng unct on acrossorganizational lines, facilitating purchasing leverages across SBUs/

    Inter-company information access - clarity of production and demandinformation residing in organizations both upstream and downstreamthroughout the chain.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    10/34

    9/22/20

    Data interchan e - between affiliates and nonaffiliated throu h standard

    telecom chinless.

    Data capture - ability to acquire data about an order at the point of origin,

    and to track products during movement as their characteristics change.

    Transformation of business from within - managers who can see the big

    picture and accept new forms of business processes and systems

    Improvement in supplier-customer relationships - to justify investment in

    technolo linka es.

    Dr.V.K.Gupta

    2. INVENTORY MANAGEMENT ACROSS THE SUPPLY CHAINTime based competition is here to stay.

    Quick response and flexibility has been imbibed in day to day culture.

    A number of companies have experienced major improvement incorporate results by focusing on cycle time - Toyota, Wall Mart,

    erox, otoro a .

    Many company follow Dock to Dock system for component supply likeFORD where supplier delivered parts are delivered directly on thelines.

    3. SUPPLY CHAIN RELATIONSHIPS

    Close relationship is the key to Supply Chain Management.

    Commitment of company to use single or dual source of supply for alon er eriod. Few select su lier is better to work with.

    A degree of trust is essential for smooth flow of materials andinformation.

    A key element in improving performance is the presence of objectiveperformance measures, both parties are operating acoding toexceptions and meting stated objectives.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    11/34

    9/22/20

    CORPORATE PROFITABILITY LINK TO SUPPLY CHAIN

    Reduction in costs - Concept of supply chain crosses over theboundaries of an organization. Collaborative efforts with the upstreamvendors and suppliers, and with downstream distribution channelpartners and customers offer opportunities to avoid non value addingact v t es, re uce transact on costs, r ng econom es to operat ons.

    Total sourcing - Manufacturers have focused on minimizing price byhaving many vendors each fighting for his share. Holistic view ofsupply chain reveal that suppliers cost are in effect the cost of themanufacturer. If a supplier is forced to hold more inventory, its costwill find its way in supplier's price.

    Gain sharing - Companies striving to become lean manufacturershave started recognizing the need to develop co-operative relationshipwith vendors to reduce costs and improve efficiency. ChryslersSupplier cost reduction program, where they agreed to share gains

    with suppliers. 185 suppliers submitted proposals to save $ 1.23billion, out of which Chrysler retained $320 million. Rest was sharedby others.

    Dr.V.K.Gupta

    Information sharin - Vendors are iven access to roduction

    schedules while buyers monitor stock levels with vendors. Based on

    agreed schedule vendor manage raw material, manufacture and deliver

    them just in time.

    Collaborative partnership - Radical steps of jointly creating business

    plans. M&M reduced its first tier suppliers and rationalized suppliers

    in three tiers. Companies work closely with first and second tier

    suppliers to redesign even the manufacturing process.

    Working capital - Reduced working capital across chain Reduced Assets - Less assets across the supply chain due to better

    utilization of assets.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    12/34

    9/22/20

    Competitive Manufacturing

    Proactively contributing to making total supply chain moreefficient and flexible

    --- mass customization.

    Place agility - Firm that is manufacturing same product at a number oflocations, benefits by investing a little more in excess capacity. Thisextra capacity enables manufacturer to shift base quickly based oncurrency fluctuations or other changes.

    Postponement - Individual customers need can be fulfilled bypostponement, in place of stocking many SKU with similar items.

    xamp e - rac e was pac e n our com na ons w c n urnwas packed in four packing for 4 different customers making 16 SKU.Solution was to manufacture bracket but pack at distribution centre.Similar strategy is now used by paint companies to handle numerousshades and colors without adding to the inventory.

    Dr.V.K.Gupta

    Mer e in transit - This can be defined as co-ordination of com lete

    shipment to a customer, done through a pre-consolidation of

    components at an established point, free of any inventory and

    strategically located in the supply chain. Benefit is in inventory

    reduction, cycle time reduction and reduction in transportation cost.

    Production in consumption - Sell one - build one. Product is not

    assembled till order is processed. This concepts is used for high value

    consumer durable so that production closely follows consumer

    preferences and avoids high finished good. It needs fast orderprocessing, optimum inventory levels, sophisticated forecasting,

    modular design and flexible manufacturing.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    13/34

    9/22/20

    Role of Information Technology in Supply Chain

    Management

    Inventory Management

    Distribution Management

    Channel Management

    aymen anagemen

    Financial ManagementSales Force Management

    Dr.V.K.Gupta

    Information Technology Degree of integration of IT with Supply Chain

    EDI (Electronic Data Interchange) - The electronic transaction setsEDI - invoice, quotes, purchase orders, standard business

    ,communicate with computer in another organization, eliminatinghuman involvement and effort. Systems in both companies can bedifferent.

    ERP - Comprehensive planning and control framework. Has built inRDBMS, JIT practices, CIM concepts, client server architecture, andproven good management practices and internet.

    APS -Advanced Planning Systems work on theory of constraint., can

    oo a a e resources s mu aneous y an g ve op m ze so u ons.Solutions are available for Advanced forecasting, DemandManagement, Manufacturing and scheduling, warehouse management,transportation management.

    Internet - Intranet, Extranet, WWW

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    14/34

  • 8/8/2019 Supply Chain1

    15/34

    9/22/20

    Why E-SCM?Globalization - SC is no longer bounded by geographical boundary.

    Industry and Product Convergence - Mega mergers and the use bycompanies to move into new sectors ( like retailers into banking ) ischanging the way business view competition and cooperation.

    Increasing sophistication in the supply chain - Shareholders value can beenhanced through integration of the supply chain.

    Greater information integration - Now more companies are adoptingstandard software like ERP and specific supply chain software. It shouldbe easy to plug in new elements of supply chain with speed and ease.

    Rise in B2B e-Commerce - Companies prepared for an e-synconized SCwill be best positioned in future.

    - -into partnerships to maximize their returns. E-SC makes company moreattractive partner.

    New types of employees incentives - Leading companies encourageemployees to satisfy customers needs through collaboration.

    Dr.V.K.Gupta

    E-SC

    Reducing operating costs

    Improving management and control

    Decreasing cycle time

    Delivering bottom line befits.

    In future following will drive E-SC

    Highly sophisticated customers with high expectations

    Waning days of reengineering

    Simplicity in technology

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    16/34

    9/22/20

    TRADITIONAL ORGANIZATION STRUCTURE

    CEO

    Marketing Manufacturing Finance Information

    Systems

    Customer Service Logistics

    Transport Warehouse

    Dr.V.K.Gupta

    LOGISTICS IN THE MIDDLE ORGANIZATION

    Information system Corporate strategy Customer

    control development

    Human Facilitating Supply Chain

    Resources interaction Manager

    Procurement MaterialsLogistics & inventory

    operations

    Supplier Manufacturing

    Service provider

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    17/34

    9/22/20

    THIRD PARTY RELATIONSHIP

    A planned ongoing relationship where both parties have needs that

    other party can fulfill and both parties share values, goals and

    corporate strategies for mutual benefits.

    Outsourcing (Functional relationship)

    A specific defined relationship that is contractual and dependent on

    supplier meeting the shippers defined performance criteria.

    Operational ( Transactional relationship )

    An operational relationship based on a single event or a series of

    separate single events.

    Dr.V.K.Gupta

    INTERDEPENDENT KEY DIMENSIONS

    Process integration

    In-depth knowledge of each others

    business

    Open information exchange

    Compatible value

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    18/34

    9/22/20

    OPPORTUNITIES FOR STIMULATING

    FOCUS ON LOGISTICS

    Service

    Customer service

    Added value

    Customization

    Costs

    Warehousing

    Inventories

    Administration

    Trans ortation

    Environment and Safety

    Storage and transportation Responsive care

    Packaging

    Dr.V.K.Gupta

    COMPETITIVE SUPPLY CHAIN

    Competitive position

    Organizational complexity

    Total cost or long term profitability

    End customer satisfaction

    Supply chain alignment

    Im roved customer service

    Shorter lead times

    Lower costs

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    19/34

    9/22/20

    Sourcing Strategy

    1. Make or buy 2. Manufacturing M.

    3. Capacity Management

    1. Channel Selection, 1. Demand forecasting

    2. Supply chain configuration 2. Facility planning

    3. Distribution planning 3. Inventory planning

    Strategic Supply chain

    Management

    Customer Service Integration Strategy

    Strategy 1. Information integration1. Service needs 2. Decision integration

    2. Service cost 3. Financial integration

    3. Revenue management

    ELECTRONIC VALUE CHAIN MANAGEMENT

    Inbound supply chain management -

    TELCO used its VCM, a web based solution for itsinbound logistics. 1000 suppliers.

    -- Online PO

    Online delivery schedules

    Real-time goods status information

    Payment information

    Instant delivery schedule change notifications

    Downloads reports in various formats for integrating with suppliers.

    Benefits Effective inventory control

    Fewer stock outs

    Saving in administrative costs - telephone, fax, visits

    Increased operating efficiency

  • 8/8/2019 Supply Chain1

    20/34

    9/22/20

    KINETIC MOTORS - Online Solution

    Online solution based on Value Chain Management , a web basedsolution, covering Vehicle Sales, Warranty and Spare parts.

    System features

    Online ordering

    Vehicle order processing and tracking

    Real-time statement of account

    Payment information

    Workflow automation, chat, board, email

    Online warranty registration

    Online warranty claim

    Download of re orts

    Benefits

    Faster ordering and delivery

    Lower transaction cost

    Saving in administrative cost

    Increase in operational efficiency

    ELECTRONICS CO. REDUCES INVENTORY & COST

    ABC took warehouse usage as a measure to reduce inventories. It was

    running at 16 days in 98-99. Problem identified was lack of reliable

    forecast which was being compensated by excess production. The

    distribution efficiency was 68% measured by model mix and JIT

    delivery. Even though the company was linked to sales points and

    depots, it looked for solution. One of this was to optimize warehouse

    space. 5S system was adopted to improve the warehouse floor space

    and visual management. Floor space index linked storage was

    introduced. It was 2.2 ft. per unit in the beginning. Every year Co.

    allocated limited space for each product line in the warehouse based on

    . .

    adjusted based on actual sales of relevant line. This slashed the

    inventory to 7 days from 16 Days.

  • 8/8/2019 Supply Chain1

    21/34

    9/22/20

    Inbound logisticsIndigenous- 5 days Raw Material Manufacturing

    Supplier Stores 10days process -5 days 7 daysImported - 30 days

    are ous ng10 days

    1 day 3 days 8 days

    District centers Zonal Centers

    Dealers 10 days 15 days

    Operations

    Supply chain of a tyre company

    Dr.V.K.Gupta

    TYRE CO. REDUCES INVENTORY & COST

    A tyre Co. had finished inventory of 50 days in 96. The co. system was

    plagued by transit time delays as it had multiple manufacturing

    locations, 125 selling points, 300 SKUs. There was a mismatch

    between tyre and tube production and the production was not in sync

    with planning. Due to lack of coordination's even local dispatches took

    3 days.

    Co. set up 6 divisional dispatch centers in metros across the country.

    This was done after plotting location of all 125 sales points and

    drawing circles with radii of 48 hours travelling time to cover all the

    po nts. o on y ours not ce was nee e to rep en s t e stoc .network was set up to enable distribution centers to communicate

    demand to the plants on JIT basis. They have been able to reduce

    inventory to 25 days and now aim at 10 days.

  • 8/8/2019 Supply Chain1

    22/34

    9/22/20

    SC Solutions in Automobile Industry

    Caterpillar's Performance Engine Products Divisionimplemented I2 solutions for demand management,

    ,

    scheduling. They have reduced product inventory by $ 32

    million, cut assembly cycle time by 38% and eliminated

    80% of their assembly line changes.

    DaimlerChrysler links multidisciplinary platform teams

    together using I 2 collaborative solutions. DaimlerChrysler

    both new and existing products reducing time to market

    and saving a projected more than $ 1 billion indevelopment and new vehicle launch costs.

    Dr.V.K.Gupta

    Fords Woodhaven Stamping facility implemented I 2solutions to reduce work in process inventories by $ 3million, plus another $ 2 million in increased throughputand reduced overheads.

    General Motors CAMAS project proactively managessuppliers capacities to resolve excesses and shortages inthe supply chain and create visibility into the capacityconstraint. The system handles GMs 20 plants in Europeand 40,000 parts manufactured by 2000 Tier 1 suppliers.

    Toyota Motor Sales USA accessories and replacementparts business uses I 2 software to provide total inventory

    dealers. Accurate delivery date quoting, improvedforecasting, optimized inventory replenishment areexpected to save $ 30 million.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    23/34

    9/22/20

    Renault used I 2 demand lannin and collaborativesolutions for its new distribution project targeted atdelivering cars within 15 days of taking customer order,cutting car inventory by half and reducing delivery costs.

    Engine manufacturer Cummins employed assembly linesequencing and factory panning solutions to dramaticallyincrease throughput. While reducing overheads. It reduced

    shortages.

    Volkswagen in using I 2 to build global digitalmarketplace to its suppliers. Goal is to achieve a saving of& 200 per vehicle.

    Dr.V.K.Gupta

    Shell Chemicals- Lotus notes as its Extranet

    Shell Inventory Managed Order Network

    e ore

    Customer ordered based on reorder level,

    usually late, resulting in rush order.

    It takes about 2 weeks of order to be delivered

    to customer through rail car, which is weighed

    at both ends. Billing for each rail car was difficult and late.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    24/34

    9/22/20

    Now with SIMON - System( NOTES based )

    The amount of product consumed in last 24

    hours

    The amount of new product the arrived and was

    unloaded

    urren an an c pa e pro uc on sc e u es

    Known changes in the schedules

    It is automatically reconciled with SAP MRPsystem.

    Shell Account service rep ( ASR ) is presentedwith the supply plan. If plan indicates inventorylevels at customer low, ACR fills a electronic POand informs new shipment to customer.

    SIMON was introduced to 23 main customers. In12 months 20 million additional sales re orted.

    Now it will be extended to 50 customers.

  • 8/8/2019 Supply Chain1

    25/34

    9/22/20

    SIMON, a Lotus NOTES based system, enablesthe transfer of responsibly for inventorymanagement rom customer to supp er.

    Through SIMON, we are able to proactively keepvital inventory on their shelves.

    Customers pay for only what they consume.

    Shell is the sole supplier.

    s us ness mo e s u on rus an mu uarelationship and a belief that both would benefit

    significantly by this initiative.

    Benefits to customers - Eliminates expensive excess inventory

    Facilitates timely, low cost re-synching ofsupply chain

    Ensures the product is on site whenever needed

    Ensures quick response for changing conditions

    Eliminates erratic pattern

    Reduces order processing overheads Streamline financial statement and

    reconciliation processes.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    26/34

    9/22/20

    DISTRIBUTOR - MANUFACTURER

    INTEGRATION

    Thomas & Betts, manufacturer of electrical.

    What Thomas & Betts committed to do under theprogram was amazing. But the distributor had tocommit also.

    The distributor gains through inventory levels, serviceperformance, receiving efficiency and accountspayable productivity.

    Total operating cost could drop by 8-10% of the dollarsales. The distributor had to agree to 75% of his stockwith T & B products.

    Dr.V.K.Gupta

    How it works T & B and distributor identified the slow moving

    products.

    .

    If a competing line is replaced, T & B allowsdistributor to replace gradually the old products.

    T & B takes over the job of deciding when and howmuch to ship to the distributor.

    Five full time planners evaluate distributors salesfigures, forecast needs, set replenishment controls in

    T & B computer, automatically send replenishmentstock when time comes.

    Distributor must transmit end of day stock on eachitem via EDI or personnel computer.

  • 8/8/2019 Supply Chain1

    27/34

    9/22/20

    There are no requirements in terms of

    how large a shipment must be. Weekly of

    twice / week.

    T & B pays all freight.

    Approximately 1000 items are designed

    as super stock. These are shipped in 48

    hours.

    Order Performance in pilot was 98%.

    Shipment accuracy was 99.7%.

    Dr.V.K.Gupta

    T & B packages each item separately and prints oneach carton distributors warehouse locations.

    Distributor does not receive each item separately.e recor o a s pmen as arr ve . ac ng s p s

    99.7% accurate. Items are received directly in stock.

    Each carton is taken directly to warehouse locationfor opening, unpacking and put away. It saves 90%in labour.

    If a shortage is discovered, T & B acceptsdistributors word and ad ust the invoice

    immediately. Five days are allowed to report error.

    Involving is delayed till system shows all items arereceived OK.

    This avoids issuing of credit notes etc. Each invoiceis correct.

  • 8/8/2019 Supply Chain1

    28/34

    9/22/20

    Invoice reconciliation is automatic, hence it isposted in distributors account payable withoutany tem y tem c ec . nvo c ng s one oncea month.

    Distributors reported 80% saving in accountpayable activity.

    Material can be returned 4 times a year with norior a roval of T & B. Distributor does not

    have to worry about when purchased, at what

    cost, OK ot not etc. Distributor does not have to pay freight.

    Dr.V.K.Gupta

    Benefits

    Distributors - In addition to Receiving, warehousing and

    accounting savings, average inventory dropped by 45%.

    T & B - As a result of savings, distributors started lowering

    price. One distributor increased sales of T & B products by

    80% in one year.

    Commitments made by distributor

    75% of T & B items in their stock.

    .

    Will inform additional market / trend information to T & B

    planner not appearing in analysis of past sales.

  • 8/8/2019 Supply Chain1

    29/34

    9/22/20

    B-2-C VALUE CHAIN

    Component BE DIRECT

    Supplier DELL CUSTOMER

    Money Money

    Prof. Ushio Sumita

    Globalizing TraditionalJapanese Procurement System

    Case of Toyota

    Fair and impartial activity based on open door

    policy

    Win-win relationship with suppliers based onmutual trust and long term prosperity

    To be ood cor orate citizen in localcommunity - social and economic contributionto local community

    Achieve global optimal through above

    Prof. Ushio Sumita

  • 8/8/2019 Supply Chain1

    30/34

    9/22/20

    Core of Toyotas Global Procurement

    System

    ,

    supplier to compare its price with prices of other

    suppliers for all parts

    New Supplier / New Technology for finding new

    competitive suppliers and new technologies

    -

    make current suppliers more competitive

    Prof. Ushio Sumita

    New Suppliers / Global Price Kaizen-Support

    New Technology Comparison System System for

    Development Program Current Suppliers

    New Suppliers Current

    Suppliers

    Development Global Price

    Program Comparison Database Support

    Program

    oyota expectat onSystem

    Procurement Supplier Selection

    Strategy and Order

    Prof. Ushio Sumita

  • 8/8/2019 Supply Chain1

    31/34

    9/22/20

    SUPPLY CHAIN IN THE FUTURE

    Recycled supply chain - Using sully chain as a closed loop to collectproducts at end of its life and recycle parts and materials -

    Refurbishing and recycling used parts can be source of revenue.

    Supply chain designed for flexibility and responsiveness - Normally

    supply chains are static. It is better to design supply chain for

    flexibility since conditions keep on changing quite fast.

    Virtual supply chain - The future supply chain will create a virtual

    organization based on intellectual capital. These organizations may not

    have any assets of their own. Each of these may be outsourced.

    Naturally aligning components - Today components of supply chain

    are designed to produce a best overall performance. In future it may be

    modular where components may adjust to changes in other

    components and external environment of supply chain.

    Dr.V.K.Gupta

    Efficient and Responsive Supply Chain

    External Perspective Internal Perspective

    Improved Improved Value added Reduced costs Increased Improved quality

    delivery responsiveness services flexibility

    Reduced order cycle Reduced product Reducing Mater ia l Offer var ious Improved

    time development time customer Labour product types reliability

    On-time and Flexible product inventory Overheads Expand Doing things

    complete delivery design Providing spl. Corporate offering more right first time

    Customised delivery Better after sales packaging overheads frequently

    service Improving

    customers

    business system

    Increased

    profitsAccelerated

    growth

    Customer

    delight

    Greater

    share

  • 8/8/2019 Supply Chain1

    32/34

    9/22/20

    ISSUES FOR AUTOMOTIVE INDUSTRY

    Order taking and Production planning

    Dealers send orders to regional offices, which in turn are sent to- , , .

    Bull Whip Effect ).

    Based on sales plans, 6 month production plans and monthlyschedules ( Firm + Tentative ) are made and sent to vendorsthrough fax or conventional means.

    Local replenishment

    For direct resources, push system of replenishment based i.epurchase orders in advance based on production plans andforecast. No EDI or IT. At best email.

    Very few items on JIT ( 20%) . Delivery 3-4 times a day.

    For indirect resources, procurement tender based. Orderingperiodically using paper.

    For JIT items, inventory 4 hours, for other 2-4 days.

    Dr.V.K.Gupta

    Overseas replenishment

    10-15% components imported from parent company /collaborator. Kit ordering for 6 month ( rolling) using email.

    Payments

    As per terms ays most y ). ayment proce ure manua .Internal process automated.

    Logistics

    The transportation is vendor arranged.

    Mix of spoke and wheel and milk round for planed orders.

    No EDI for information on impending delivery.

    Vendor structure

    Few tired vendors. Mostly direct vendors. Cost of quality onus lies on vendors.

    None of the vendors have EDI or any other links withmanufacturer.

    Dr.V.K.Gupta

  • 8/8/2019 Supply Chain1

    33/34

  • 8/8/2019 Supply Chain1

    34/34

    9/22/20

    How the Quality is changing the chain?

    Customers are defining quality standards that entire

    supply chain must meet

    Suppliers are conforming to their buyers JIT and lean

    manufacturing systems

    Manufactures are partnering their vendors in determining

    designs and product specification upfront

    Com anies are assin on the cost of oor ualit to their

    vendors instead of taking them on themselves

    Dr.V.K.Gupta

    How cost management is changing the chain?

    Demand forecast tools are being used to micro tailor orders

    for suppliers

    Inventories are being decimated as companies are soucing

    on need based system

    Manufactures are setting target costs to their suppliers

    instead of asking for the price

    Companies are helping their vendors lower their

    production costs so as to pay lower prices

    Dr.V.K.Gupta