Zara is a fashion retailer established in 1975 by the Spanish group Inditex founded by Amancio Ortega Gaona. Inditex runs over more than 5400 stores worldwide and owns brands other than Zara such as Massimo Dutti, Breshka, Oysho, Pull and Bear and Stradivarius. Inditex headquarters are located close to La Corua in northwestern of Spain. The old shipbuilding town of La Corua seems an unlikely home to a tech-charged innovator in the fashion industry. But thats where the Inditex Corporation built its headquarter called The Cube.
The brand succeeds to make moderate prices with a large choice of new clothes every time. Zaras short lead-time system depends on continuous exchange of information throughout every part of Zara's closed loop feedback system (Figure 1). This chain goes from customers to store managers, then to market specialists and designers, then to production staff, from buyers to subcontractors, from warehouse managers to distributors, and so on. Unlike other retailers Zara's organization, operational procedures, and even its office layouts are all designed to make information transfer easy. Zara's employs 200 designers who sit in the center of production center. Zara produces about 11,000 styles each year- perhaps five times as many as competitors. This allows Zara to supply its stores with new styles every two weeks. The store specialists work in the same room as designers and review store sales and speak with store managers to get their feedback.
Figure
1
Zaras production center consists of three spacious halls: women's clothing lines, men's and children's. Unlike most companies, which try to excise redundant labor to cut costs, Zara makes a point of running three parallel, but operationally distinct, product families. Accordingly, separate design, sales, and procurement and production- planning staffs are dedicated to each clothing line. A store may receive three different calls from headquarters in one week from a market specialist in each channel. Although it is more expensive to operate three channels, the information flow for each channel is fast, direct, making the overall supply chain more responsive. The stores act as market information gathering terminals, providing feedback to the design teams. Zara is careful about the way it deploys the IT tools to facilitate its information exchanges. PDA computers and phone calls help bringing the information from all the stores to La Corua and to headquarters; such hard data as orders and sales trends and such soft data as customer reactions and the "buzz" around a new style. While any company can use PDAs to communicate, Zara's fast paced organization ensures that important conversations don't fall through the bureaucratic delays. By reducing the quantity of manufacture style, Zara not only reduces its exposure to any single product but also creates artificial scarcity. Every two weeks Zara introduces new products in small quantities, reduces the usual costs associated with running out of any particular item and markdown management. Although Zara may not be able to meet the customers demand but empty racks don't drive customers to other stores because shoppers always have new things to choose from. In fact, Zara has a policy of moving unsold items after two or three weeks. This can be an expensive practice for a typical store, but since Zara stores receive small shipments and carry little inventory, the risks are small; unsold items account for less than 10% of stock, compared with the industry average of 17% to 20%. Furthermore, new merchandise displayed in limited quantities and the short window of opportunity for purchasing items motivate people to visit Zara's shops more frequently than they might other stores (17 times annually on average for Zara,
compared
to
4
for
other
stores).
The
high
traffic
in
the
stores
circumvents
the
need
for
advertising:
Zara
devotes
only
0.3%
of
its
sales
on
ads,
far
less
than
the
3
to
4%
its
rivals
spend.
A
key
point
in
Zaras
strategy
that
helps
the
brand
differentiate
itself
from
the
other
competitors
resides
in
their
high
turnover.
According
to
what
we
know
from
their
current
logistics
situation,
they
have
developed
a
large
network
in
their
supply
chain
mostly
in
Spain
and
Portugal,
and
trying
to
outsource
as
few
quantities
as
they
can
in
order
to
respond
quickly
to
the
demand
of
its
customers
(only
30%
of
their
production
comes
from
Asia).
No
other
competitor
such
as
H&M
has
managed
to
create
this
kind
of
situation,
as
these
brands
are
generally
cost-oriented,
and
will
therefore
choose
to
outsource
the
biggest
part
of
their
production,
in
order
to
produce
large
batches
that
will
then
be
sent
to
the
shops.
As
Zara
is
historically
a
European
brand,
with
a
strategy
based
on
quality
and
frequent
changes
in
the
fabrics
and
styles,
it
has
enabled
Zara
to
build
the
whole
process,
from
design
to
stores,
as
a
very
confined
one.
5. Threat
of
Substitute:
The
fashion
industry
is
unpredictable
to
project
the
next
big
trends.
Though
Zara
distinct
from
others
by
continuous
innovation
and
creative
design
(every
two
weeks)
of
most
up-to-date
fashion.
Internet
is
a
potential
threat
for
Zara
as
it
expands
the
size
of
the
market
(for
example,
with
Asos.com).
Barriers
to
Copy
Studying
in
detail
the
current
situation
of
Zara
and
seeing
that
they
are
especially
successful
in
their
management
(their
financial
results
exceed
those
of
their
competitors
by
far),
we
can
wonder
why
no
other
brand
has
tried
to
copy
their
current
approach.
Even
if
the
whole
process
seems
clear
in
the
eyes
of
other
competitors,
the
biggest
barrier
to
copy
Zaras
approach
is
the
capital
needed
to
invest
in
such
a
system.
Being
able
to
struggle
against
such
a
big
player
in
the
fashion
industry
requires
money
but
also
enough
knowledge
in
design,
operations,
in
order
to
meet
customers
demand
and
build
a
strong
network.
Zara
does
not
need
high
level
of
expenditures
on
advertising
to
please
its
customers
and
to
expand
its
market
share.
However,
for
a
new
entrant,
it
will
be
harder
to
succeed
without
advertisement
considering
the
current
number
of
brands
that
have
been
developed
in
this
market.
It
may
seem
strange
that
Zara
does
not
spend
money
on
advertising.
But
on
the
other
side,
their
advertising
investments
reside
in
the
choice
of
locations
for
stores.
The
better
the
location
is,
the
higher
visibility
the
brand
will
have,
and
the
higher
the
reputation
of
the
brand
will
be.
Consequently,
to
be
able
to
manage
such
expenses,
the
potential
competitor
needs
to
be
sure
about
its
future
projects
and
financial
results.
If
we
consider
now
a
current
competitor
of
Zara,
why
not
trying
to
follow
Zaras
business
model?
It
is
mostly
because
of
the
essence
of
the
brand.
If
a
competitor
was
to
try
to
imitate
this
approach,
it
would
have
to
completely
redesign
its
supply
chain,
procurement
and
production
systems,
and
it
would
be
very
costly
and
not
necessarily
efficient.
Another
point
that
represents
a
barrier
to
copy
Zaras
approach
is
its
vertical
integration
in
the
whole
process.
Being
able
to
build
the
entire
network
from
procurement
to
stores
by
linking
all
components
using
efficiently
the
information
flows
has
enabled
Zara
to
have
control
on
all
steps
of
the
supply
chain.
What
will
be
tough
if
some
brand
was
to
copy
this
approach
will
be
to
find
the
right
links
that
can
work
together
and
master
the
costs
of
such
a
channel.
Outsourcing
Zara,
unlike
its
competitors
such
as
Gap,
Benetton,
and
H&M,
does
not
rely
on
Asian
outsourcing.
70%
of
Zaras
materials
are
manufactured
in
Europe,
with
50%
made
in
Zara
controlled
facilities
in
the
Galicia
region
of
Spain
near
headquarters.
Zara
outsources
only
30%
of
its
production
outsourcing
from
Asia
and
Morocco.
Though
the
cost
of
production
in
Spain
is
17-20%
more
expensive
than
Asia,
Zara
does
have
a
competitive
advantage
over
its
competitors
in
regards
to
operations.
The
local
strategic
partnerships
that
Zara
maintains
with
manufacturers
in
Europe
allow
for
a
total
control
and
product
throughput
time
of
3-4
weeks
from
conception
to
distribution.
Zara
postpones
dyeing
and
printing
designs
until
close
to
manufacture,
thereby
reducing
waste
and
minimizing
the
need
to
clear
unsold
inventories.
The
proximity
of
these
suppliers
gives
Zara
great
flexibility
in
adapting
their
product
lines
based
on
up
to
date
market
trends
and
consumer
behavior.
It
also
decreases
costs
of
holding
inventory.
Zaras
competitors,
through
outsourcing
to
Asian
countries
such
as
China,
sacrifice
the
benefits
of
proximity
for
low
labor
and
production
costs.
Though
there
is
a
cost
advantage
in
their
approach
in
regards
to
labor,
the
lack
of
flexibility
in
changing
orders
based
on
current
trends
hinders
their
operational
efficiencies.
Inventory
costs
are
higher
for
competitors
because
orders
are
placed
for
a
whole
season
well
in
advance
and
then
held
in
distribution
facilities
until
periodic
shipment
to
stores.
This
process
has
the
advantages
of
being
very
responsive
to
any
kind
of
changes
in
demand
from
the
customers,
and
of
having
very
short
lead
times.
However,
disadvantages
of
this
system
are
two-fold.
Firstly,
it
is
very
exposed
to
a
pressure
from
the
suppliers:
if
a
supplier
decides
not
to
respond
to
the
demand
or
faces
issues
in
the
procurement,
Zara
does
not
have
another
potential
way
to
be
served.
A
second
point
to
mention
concerns
the
potential
international
expansion.
If
Zara
was
to
decide
to
increase
its
market
share
on
the
US
market
for
example,
it
would
need
to
build
a
strong
supply
chain
on
this
territory
to
be
as
efficient
as
in
Europe.
Therefore,
finding
new
resources
from
other
parts
of
the
world
should
be
a
point
to
consider
to
be
able
to
recreate
the
successful
process:
JIT
manufacturing,
high
turnover,
short
lead
times.