Instructors Profile
Name : Ameer Rizvi 1998-2001: Oracle Corp.
Presale, Business Consulting, Apps Trainer
2006-2010: IBA
Permanent Faculty Member
Class Rules
SCM Introduction Purchasing Management Supplier Relationship Demand Forecasting and Collaborative Planning Aggregate Planning
Inventory Management Process Management: JIT and Quality Management Designing Distribution Network Domestic and International Transportation Information Technology in SCM
Other Assignments
SCM Survey SCM Case Studies SCM Games SCM Articles and Videos (from the Internet) SCM Term Paper (Includes SCM Workbook)
Grading
1st & 2nd Term 30 Marks Final 30 Marks Term Report (Including Survey) 30 Marks Presentation 10 Marks
Total
100
Marks
SCM
1-9
What is a Supply Chain? Objectives of a Supply Chain. The Importance of Supply Chain Flows Tends in Supply Chain Decision Phases in a Supply Chain Process View of a Supply Chain Examples of Supply Chains
Wholesalers, distributors
Retailers
End Customer
Managing Flows
Product and Services flow
Information Money
Supplier
Manufacturer
Distributor
Retailer
Customer
Supply chain management is the management of flows between and among supply chain stages to maximize total supply chain profitability
Channels of Distribution
Producer Agent/Broker Wholesaler Channel 1 Channel 2 Channel 3 Retailer Users
Organizational Scope of Supply Chain Management Demand Forecasting Purchasing & Supplier Management Production / Manufacturing Inventory Management Warehouse Management Logistics / Distribution New Product Development
Primary activities
Inbound logistics Operations Outbound logistics Marketing and Sales Service Corporate infrastructure Human resources management Technology Development Procurement
Materials receiving, storing, and distribution to manufacturing premises Transforming inputs into finished products. Storing and distributing products Promotions and sales force Service to maintain or enhance product value Support of entire value chain, e.g. general management planning, financing, accounting, legal services, government affairs, and QM Recruiting, hiring, training, and development Improving product and manufacturing process Purchasing input
Exercise
Design a high level model of an Organization depicting the Product and Information flow within the departments of the organization
Customer is an integral part of the supply chain Includes movement of products, information, and funds in both directions Potential stages in a Supply Chain
Supplier
Manufacturer
Distributor
Retailer
Customer
Wholesalers, distributors
Retailers
End Customer
1-22
Plastic Producer
Tenneco Packaging
1-23
Plastic Producer
Tenneco Packaging
Paper Manufacturer
Timber Industry
1-24
the cost Longer the lead time More Inventory build ups (Higher Inventory Cost) Information mismanagement
Channels of Distribution
Producer Agent/Broker Wholesaler Channel 1 Channel 2 Channel 3 Retailer Users
Responsivene ss
Affordabilit y
Quality
build ups Very Long Lead Times Poor Information Flow among supply chain partners Poor Material flow among supply chain partners Poor Demand Forecasting
Poor Quality of the Finished Products Poor Supplier Management Excess Inventory Inventory Stockout Poor Production Scheduling Poor warehouse Management Lack of departmental Coordination Poor Demand Forecasting Poor Purchasing Management
Poor Quality of the Finished Products ( TQM and Six Sigma) Poor Supplier Management (Supplier evaluation & Certification) Excess Inventory (JIT, ERP Procurement and Visibility) Inventory Stockout (ERP Inventory Management) Poor Production Scheduling ( MRP Planning and Production) Poor warehouse Management ( ERP Warehouse Management) Lack of Partner Coordination (Supplier Management and
Helps in the Integration of all the departments of an organization (improve coordination and communication) Helps in the optimization of
Demand Forecasting Purchasing & Supplier Management Production Inventory Management Warehouse Management Logistics New Product Development
the more efficient the response the more timely the supply of goods resultant costs reduced
1-35
Compaq estimates it lost $.5 billion to $1 billion in sales in 1995 because laptops were not available when and where needed When the 1 gig processor was introduced by AMD, the price of the 800 mb processor dropped by 30% P&G estimates it saved retail customers $65 million by collaboration resulting in a better match of supply and demand
Relationships allow the trust to share Accuracy assures information is useful Responsiveness builds the relationships
Poor Performance
Good Performance
Wholesalers, distributors
Retailers
End Customer
Reduce Cost
(Maintain/ Improve Quality and Customer Services level)
Optimize the profitability of all of the supply chain partners through customer satisfaction
Example: Dell receives $2000 from a customer for a computer (revenue) Supply chain incurs costs (information, storage, transportation, components, assembly, etc.)
Difference between $2000 and the sum of all of these costs is the supply chain profit
Supply chain profitability is total profit to be shared across all stages of the supply chain
Supply chain success should be measured by total supply chain profitability, not profits at an individual stage
Raw Material ( Supplier ) Internal Cost ( in the Value Chain) Information Management Cost Channel Members Markup Services
Procurement Manufacturing Inventory Management Marketing Inbound and Outbound Logistics Warehousing Administrative Others
Customer
Manufacturers Cost Manufacturers Markup Wholesalers Markup Retailers Markup Customers Price
Firms with?
Large inventories Large number of suppliers Complex products Customers with large purchasing budgets
Bullwhip Effect- the magnified reduction of safety stock costs based on coordinated planning and sharing of information (Information replaces
planning, forecasting, and replenishment activities reduce the Bullwhip Effect and lead to better customer service, lower inventory costs, improved quality, reduced cycle time, better production methods, and other benefits.
Course Content
Wholesalers, distributors
Retailers
End Customer
Purchasing Trends:
Long
evaluation (determining supplier capabilities) Supplier certification (third party or internal certification to assure product quality and service requirements)
Strategic
Operations Trends:
Demand
management- match demand to available capacity Linking buyers & suppliers via MRP and ERP systems Use JIT to improve the pull of materials to reduce inventory levels Employ TQM to improve quality compliance among suppliers
54
Distribution Trends:
Transportation
management- tradeoff decisions between cost & timing of delivery/customer service via trucks, rail, water & air Customer relationship managementstrategies to ensure deliveries, resolve complaints, improve communications, & determine service requirements Network design- creating distribution networks based on tradeoff decisions between cost & sophistication of distribution system 57
Chain Process Integration- when supply chain participants work for common goals. Requires intrafirm functional integration. Based on efforts to change attitudes & adversarial relationships
Proper SCM
Proper SCM
Proper SCM and inventory management requires coordination of all activities and links in the supply chain to:
Ensure that goods move smoothly and on time from suppliers to customers Keep inventories low Keep costs down
Primary activities
Inbound logistics Operations Outbound logistics Marketing and Sales Service Corporate infrastructure Human resources management Technology Development Procurement
Materials receiving, storing, and distribution to manufacturing premises Transforming inputs into finished products. Storing and distributing products Promotions and sales force Service to maintain or enhance product value Support of entire value chain, e.g. general management planning, financing, accounting, legal services, government affairs, and QM Recruiting, hiring, training, and development Improving product and manufacturing process Purchasing input
Wholesalers, distributors
Retailers
End Customer
Supply chain partners depend on each other Partners dont always work together toward the same goal
SCM
What is a Supply Chain Model ? What is the Distribution Model ? SCM Process ? What is Cycle View and Push & Pull View ? When to take the customer order ? How to determine Lead Time?
Wholesalers, distributors
Retailers
End Customer
Channels of Distribution
Producer Agent/Broker Wholesaler Channel 1 Channel 2 Channel 3 Retailer Users
Wholesalers, distributors
Retailers
End Customer
Cycle view: processes in a supply chain are divided into a series of cycles, each performed at the interfaces between two successive supply chain stages Push/pull view: processes in a supply chain are divided into two categories:
Executed
Retailer
Replenishment Cycle
Distributor
Manufacturing Cycle
Manufacturer
Procurement Cycle
Supplier
order cycle (customer-retailer) Replenishment cycle (retailer-distributor) Manufacturing cycle (distributor-manufacturer) Procurement cycle (manufacturer-supplier)
Product availability Achieve economies of scale Reduce the cost of receiving the order
Retailer
Replenishment Cycle
Distributor
Manufacturing Cycle
Manufacturer
Procurement Cycle
Supplier
Involves all processes directly involved in receiving and filling the customers order Customer arrival Customer order entry Customer order fulfillment Customer order receiving
Replenishment Cycle
All processes involved in replenishing retailer inventories (retailer is now the customer) Retail order trigger Retail order entry Retail order fulfillment Retail order receiving
Manufacturing Cycle
All processes involved in replenishing distributor (or retailer) inventory Order arrival from the distributor, retailer, or customer Production scheduling Manufacturing and shipping Receiving at the distributor, retailer, or customer
Procurement Cycle
All processes necessary to ensure that materials are available for manufacturing to occur according to schedule Manufacturer orders components from suppliers to replenish component inventories However, component orders can be determined precisely from production schedules (different from retailer/distributor orders that are based on uncertain customer demand) Important that suppliers be linked to the manufacturers production schedule
Primary activities
Inbound logistics Operations Outbound logistics Marketing and Sales Service Corporate infrastructure Human resources management Technology Development Procurement
Materials receiving, storing, and distribution to manufacturing premises Transforming inputs into finished products. Storing and distributing products Promotions and sales force Service to maintain or enhance product value Support of entire value chain, e.g. general management planning, financing, accounting, legal services, government affairs, and QM Recruiting, hiring, training, and development Improving product and manufacturing process Purchasing input
Business Processes
Make to Stock ? Assemble to Order? Make to Order ? Design to Order ( Engineer to order)?
Design to Order
Make to Order
Assemble to Order
Make to Stock
Design
Test
Stock as Inventor y
Sub Assembl e
Final Assembl e
Procure
Design to Order
Make to Order
Assemble to Order
Make to Stock
Design to Order
Design (Unique Engg. Design or Significant Customizatio n Procure (RM, Standard Component , ETC Fabricat e Sub Assembl e Final Assembl e Pack and Ship
Test
Make to Order
Stock Compone nt Design Procure Design & Standard Part (Custom Design if required)
Fabricat e
Sub Assembl e
Final Assembl e
Test
Assemble to Order
Sub Assembl e
Design
Procure
Fabricate
Test
Make to Stock
Design Procure Fabricate Sub Assembl e Final Assembl e Test Stock as Inventory Pack and Ship
Make to stock
Design
Test
Stock as Inventor y
Make to stock
MAKE TO STOCK. Refers to a product environment where products can be and usually finished before receipt of a customer order. Customer orders are typically filled from existing stock, and production orders are used to replenish those stocks. This is mass manufacturing with pushing the sales philosophy. Stock
Sub Final Fabricat Procure Assembl Assembl e e e Test as Inventor y Pack and Ship
Design
Make to stock
Customer Order
Design
Test
Stock as Inventor y
Assemble to Order
Design
Final Stock Assembl Standar e Sub d The Fabricat Procure Assembl Module Custom e e as er Inventor Selecte y d Module
Test
Assemble to Order
Denotes a production environment where goods or service can be assembled after receipt of a customers order. The key components ( bulk, semi-finished , intermediate, subassembly, fabricated, purchased, packaging, etc.) used in the assembly or finishing process are planned and possibly stocked in anticipation of a customer order. Receipt of an order initiates assembly of the customized product. This strategy is useful where a large number of end products ( Final based on the selection of options and accessories) can be Stock Assembl assembled from common components. e Standar
Design Sub Fabricat Procure Assembl e e d Module as Inventor y The Custom er Selecte d Test Pack and Ship
Assemble to Order
Customer Order
Final Stock Assembl Standar e Sub d The Fabricat Procure Assembl Module Custom e e as er Inventor Selecte y d Module
Design
Test
L.T
Make to Order
Fabricat e
Sub Assembl e
Final Assembl e
Test
Make to Order
MAKE TO ORDER. In this environment, goods or service can be manufactured / offered after receipt of a customers order. The final product is usually a combination of standard items custom- designed to meet the special needs of the customer. This gives more option( as compared to assemble-toorder) to the customer in design, aesthetics, utility, accessories, etc.
(Custom Design if required) Fabricat e Sub Assembl e Final Assembl e Test Pack and Ship
Make to Order
Customer Order
Fabricat e
Sub Assembl e
Final Assembl e
Test
L.T
Design to Order
Fabricat e
Sub Assembl e
Final Assembl e
Test
Design to Order
DESIGN TO ORDER. (ENGINEERING-TOORDER). This is a highly focused environment where the individual customer gives product specifications that require unique engineering design, significant customization in manufacturing, or even new purchased materials. Each customer order result in unique set of part numbers, bills of material, and routings. Design
(Unique Engg. Design or Significant Customizatio n Procure (RM, Standard Component , ETC Fabricat e Sub Assembl e Final Assembl e Test Pack and Ship
Design to Order
Customer Order
Fabricat e
Sub Assembl e
Final Assembl e
Test
L.T
Custom er Order
Stock Compone nt Design Procure Design & Standard Part
Fabricat e
Sub Assembl e
Final Assembl e
Test
Custom er Order
Final Assemble The Customer Selected Module
Design
Procure
Fabricate
Sub Assemble
Test
Custom er Order
Sub Final Fabricat Procure Assembl Assembl e e e Stock as Inventor Pack and Ship
Design
Test
Integrated System
Push Pull
Outbound Transportation
Cycle view: processes in a supply chain are divided into a series of cycles, each performed at the interfaces between two successive supply chain stages Push/pull view: processes in a supply chain are divided into two categories:
Executed
PUSH PROCESSES
PULL PROCESSES
PULL PROCESSES
Execution is initiated in the anticipation of a customer order Demand is not known and must be forecasted Speculative Process
Execution is initiated in response to a customer order Customer demand is known with certainty Reactive Process Pull processes are often constrained by the inventory and capacity decision that are made in the
A push and pull view of the supply chain categories processes based on whether they are initiated in response to a customer order(pull) or in the in the anticipation of a customer order (push) . This view is very useful when considering strategic decisions relating to Supply Chain Design.
Decisions Generate pick list at the warehouse Timing and size of market promotions Allocate an order to a particular shipping mode and shipment Planned buildup of inventories Subcontracting, backup locations Set a date that an order is to be filled Allocate inventory or production to individual order Selection of Modes of transportation Set delivery schedules of trucks Inventory policies Products to be made or stored at various locations Outsourcing decisions Which markets will be supplied from which locations Locations and capacities of facilities (warehouse and Production) Information systems Place replenishment order
Strategic
Planning
Operational
Decisions about the structure of the supply chain and what processes each stage will perform What are some strategic supply chain decisions? Locations and capacities of facilities (warehouse and Production) Products to be made or stored at various locations Modes of transportation Information systems Outsourcing decisions Supply chain design must support strategic objectives Supply chain design decisions are long-term and
Definition of a set of policies that govern shortterm operations Fixed by the supply configuration from previous phase Starts with a forecast of demand in the coming year
markets will be supplied from which locations Planned buildup of inventories Subcontracting, backup locations Inventory policies Timing and size of market promotions
Must consider in planning decisions demand uncertainty, exchange rates, competition over the time horizon
The goal of the Supply Chain Operations is to handle the customer order in the best possible manner.
Strategic Planning
Supply Chain Planning services configure operations to best meet projected demand levels The planning horizon ranges from developing a long term strategic outlook to developing a short term tactical production schedule
Tactical Planning Warehouse Management Transportation Management Order Management Operational Planning Inventory Management Event Management
Weeks / Months
Hours / Days
Quarters
Years
Source: BAH
Supply Chain Execution services monitor and control production operations They provide real time tracking and alert notification
Network Design
Design where to place production facilities and optimize the end to end chain Construct alternate flow scenarios that incorporate associated constraints
Anticipate demand based on historical trends and current conditions Perform what if analysis - highlight the impact of changing demand drivers
Production Planning
Production Scheduling
Supply Planning Balances unconstrained demand against high level supply chain constraints Reflect order priority and due dates
Decompose the supply plan into sub assembly / production needs by site Balance production capacity across sites
Optimize processing flows, sequence, and timing Produce a finite capacity production schedule
Quarters
Weeks / Months
Hours / Days
124
Inventory Management
Warehouse
Transportation
Management
Management
Record customer orders and track status from receipt to final delivery Direct efficient response to orders with dynamic cost / benefit analysis of options
Streamline information movement and provide tight inventory control Inventories replenished using kanban, min-max, or reorder point
Event Management
Monitor and manage critical planning and event information Broadcast alert notification and present response alternatives based on pre determined business rules
Wholesalers, distributors
Retailers
End Customer
127
foreign manufacturing, office & retail sites, foreign suppliers & customers depth- second and third tier suppliers & customers
purchasing costs Reducing waste Reducing excess inventory, and Reducing non-value added activities
Continuous
Trial
Improvement through
copy competitors
Benchmarking-
will increasingly need to be more flexible and responsive to customer needs Supply chains will need to benchmark industry performance and meet and improve on a continuous basis Responsiveness improvement will come from more effective and faster product & service delivery systems