Saurabh Nigam
India’s logistics spend is ~13% of GDP , which is amongst the highest in large
economies and which signifies high scope for logistics process optimization and
growth of organized sector
Barkawi’s logistics and supply chain practice can also target supply chain functions –
both supply chain planning and execution and procurement- within various industries
– capital goods, automotive, Telecom, Pharma etc.- in which case the addressable
market will be much bigger
Source:
1. Details included in subsequent sections of the presentation
Saurabh Nigam/ 3
Key Findings1
To begin with Barkawi India can target LSP, Express, Courier, Warehousing, 3 PL
Service Providers, Trucking, Air Freight, Road Freight, Rail Freight, Ports and
Shipping companies for its Logistics and Supply Chain Service Offering (list included)
India’s logistics and supply chain consulting market is extremely competitive with
several smaller players – ECS, Universal consulting, LCA logistics consulting, i-
maritime, Aqua MCG, Avalon Consulting – along with established Multinational
Consulting firms – Mckinsey, BCG, Accenture, Deloitte, E&Y, KPMG vying for market
share
Barkawi’s blue chip reference list, global talent pool and experience with global
supply chains and logistics would differentiate it with its competitors and help it obtain
leadership in the Indian market
Source:
1. Details included in subsequent sections of the presentation
Saurabh Nigam/ 4
Key Findings1
Barkawi India should adopt value based selling approach to build Outside-in
perspective and prognosis, using publicly available information of companies at
BSE / NSE to acquire net new customers. Optimizing sales effort with progress in
sales cycle through well thought sales methodology is key to high ROI in sales
process
Barkawi has the unique opportunity to benchmark Logistics KPIs in the Indian market
which completely lacks process maturity and benchmark measures
Non existent warehousing standards in India is another key area to target for Barkawi
Barkawi can partner and tap into various India based resources to strengthen its
roots in Inda - India Infrastructure, India Supply Chain Council, Supply Chain
Management Review, CXO Today
Saurabh Nigam/ 5
Barkawi Logistics Practice – Key Findings
Barkawi Logistics Practice Business Case Details
Logistics Industry in India
Logistics Value Chain
Sample Business Cases and Key KPIs
Saurabh Nigam: Profile and Background
Saurabh Nigam: Sample Engagement Deliverables
Appendix: Other supporting details
India’s Logistics Industry
Five year’s perspective 2006- 2010
F-06 (Rs.) F-10 (Rs.)
Saurabh Nigam/ 7
Segment specific expected growth of Logistics Industry
(%)
Transportation 20 - 25
Rail 10 - 15
Container Rail 15 - 20
Container EXIM 20 - 25
Courier 20 - 25
XPS 20 - 25
Warehousing 35 - 40
CFS 15 - 20
Shipping 10 - 15
Saurabh Nigam/ 8
Consultative approach to Sales
Barkawi should adopt a Consultative approach to Sales, forming initial prognosis, using publicly
available information in financial statements, before pitching consulting services. Optimizing sales
effort with progress in sales cycle through well thought sales methodology is key to high ROI in
sales process
Benefit Model
Peer Analysis
Trend Analysis
Saurabh Nigam/ 9
Target Customers and Partners
LSP
. AFL Pvt Ltd Road Express
Balmer Lawrie . Gati
AFL
DTDC
Overnite
Professional couriers
Saurabh Nigam/ 10
Target Customers and Partners
Warehousing 3 PL Service Providers
.
CWC
. DHL
DHL logistics
AFL
Om Logistics
Schenker-BAX
Safex
Gateway Distri Parks SembCorp
Container Corporation of India
Food Corporation of India
Sical Distriparks
Panalpina
Balmer Lawrie andCompany
Allcargo Agility
Global Logistics
Trucking
. Delhi Assam Roadways
Patel Roadways
Air Freight
. National Aviation Company of India
Jet Airways
Saurabh Nigam/ 11
Target Customers and Partners
Rail Freight Ports
. Container Corporation of India . Chennai Port Trust
(Concor)
Cochin Port Trust
Gateway Distriparks
Ennore Port
Sical Logistics
Jawaharlal Nehru Port Trust
Arshiya International
Kandla Port Trust
Non-Major Ports
Saurabh Nigam/ 12
Target Customers and Partners
Shipping
. Shipping Corporation of India
Mercator Lines
Varun Shipping
Saurabh Nigam/ 13
Potential Partners and Resources
India Infrastructure: Publishing house targeted at the very top decision makers and financial managers
in infrastructure segments (http://www.indiainfrastructure.com/mags.html)
India Supply Chain Council: Has a good presence in India and organizes events (http://
www.supplychains.in/)
Supply Chain Management Review: Globally renowned, well read in India (http://www.scmr.com/)
Saurabh Nigam/ 14
Apart from the Big 5, Barkawi faces stiff competition from
the incumbent boutique consultancy firms in SCM area
Backed by a strong
leadership team specializes Strong client base
in Supply Chain
Saurabh Nigam/ 16
Barkawi India- proposed engagement methodology
Value
Define Discovery and Execution Transfer
Validation
Activities
Validate/ confirm Understand/ Execute solution Transfer the new
executive validate company/ recommendation process to the
alignment on BU strategy and and value organization
engagement pain points through proposition Ongoing support
scope, approach, targeted interviews
timeline, Develop data
objectives and request to create a
deliverables business case
Identify key Analyze operational
business areas of and financial data
focus and pain to estimate
points where can potential cost
help unlock savings and
business value revenue uplift
opportunities
Finalize solution
recommendation
and value
Saurabh Nigam/ 17
proposition
Barkawi Benchmarking – Proposed approach
Saurabh Nigam/ 18
Barkawi Logistics Practice – Key Findings
Barkawi Logistics Practice Business Case Details
Logistics Industry in India
Logistics Value Chain
Sample Business Cases and Key KPIs
Saurabh Nigam: Profile and Background
Saurabh Nigam: Sample Engagement Deliverables
Appendix: Other supporting details
LSP Business Segments
Saurabh Nigam/ 20
Key trends are driving change in the LSP Industry
Increasing customer demands and complexity are driving the need for constant
change
Companies are Customers are Some mobile Even the best New fulfillment
sourcing, becoming more producers are LSP have Days models (e.g.
producing and demanding and launching up to 20 Sales Outstanding Global Sourcing,
selling globally sophisticated in new products a (DSO) that are Build-To-Order,
managing their year; Major 30 – 120% higher Direct Ship)
LSP need to
logistics partners retailers are than best-in-class
integrate all Open platform for
handling more companies from
parties and Industrialize easy integration,
than 20’000 SKU other industries
synchronize processes to adoption of new
execution deliver consistent System to Reduce DSO with processes and
performance at manage multitude one system from ready for new
low price of (product) order entry till technologies (e.g.
specific workflow financial RFID, Mobiles)
settlement
Saurabh Nigam/ 22
The need for constant innovation
is affecting LSP’s Business Models
Shrinking product Define core service offering for each industry you as LSP serve
lifecycles & mass Develop additional value added services and niche solutions
customization Enable rapid configuration of “custom” solutions from predefined service bundles
Seamless integration across enterprise Back Office, Core Operations and Customer
New technologies Service
Saurabh Nigam/ 23
Global Logistics Industry
Global Logistics Industry
Source : Reference to World Bank Report in SSKI & Edelweiss Report, Nov’06
Saurabh Nigam/ 24
Global Logistics Industry
Global Logistics Industry
Country’s spending on logistics management
Source : Reference to World Bank Report in SSKI & Edelweiss Report, Nov’06
Saurabh Nigam/ 25
Transportation costs are significant and are expected to
rise Globally
-Logistics and Transportation Cost
- Transportation Costs are Trending Upward -
-as % of Sales by Industry -
Other
Warehousing
12% 11.7% Inventory Carrying
10% Transportation
8% 8.5%
7.8% 7.7%
6%
4% 5.3%
2%
0% 4.6%
3.3% 3.0% 3.0% 2.1%
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Freight pricing pressure expected to continue due to fuel costs, port and rail capacity
constraints, driver shortage and supplier consolidation
Saurabh Nigam/ 26
India’s Logistics Industry
Five year’s perspective 2006- 2010
F-06 (Rs.) F-10 (Rs.)
Saurabh Nigam/ 27
India’s Logistics Industry: Key Segments
Saurabh Nigam/ 28
Break-up of India’s Logistics Industry by Modes
--------- ---------
Saurabh Nigam/ 30
Segment specific expected growth of Logistics Industry
(%)
Transportation 20 - 25
Rail 10 - 15
Container Rail 15 - 20
Container EXIM 20 - 25
Courier 20 - 25
XPS 20 - 25
Warehousing 35 - 40
CFS 15 - 20
Shipping 10 - 15
Saurabh Nigam/ 31
India’s Logistics Industry, Demand Side Growth Drivers
Automobile
India has emerged as one of the most preferred destinations for MNCs to outsource their manufacturing
activities: and for India, a multi‐billion dollar opportunity.
Third party logistics providers will play a greater role in the automotive industry in the future than merely
transporting goods. They will be required to provide end‐to‐end supply chain logistics services for which
they will have to develop requisite competencies and asset‐based networks.
Automobile manufacturers such as Hyundai, Nissan and Renault, and others such as the Nippon Yusen
Kaisha (Japan) and the GBA Group (UK) are also themselves constructing a multi‐level car park facility
inside the Chennai port —a port out of which over 100,000 cars are currently exported
.
The Rs 500 million facilities to park around 6,000 cars are likely to come up in the next few months at the
Chennai port's existing North Quay.
Retail
Retailing, which today makes up less than 4 percent of the overall market, is expected to grow to $60 Bn
& increase the overall retail market by CAGR of 21.8 percent by 2015. Organized retailing is poised to
take‐off as:
Significant mall development occurs. By 2010, there will be 600 malls and 300 million square feet,
respectively.
Reliance plans to open 4,000 stores and hypermarkets with a target of $22.3 billion in sales by 2011
Pantaloon aims to grow its stake hoping to top $6 billion by 2011 by opening an additional Big Bazaars
Others specialize.
Tata group, in a joint venture with Woolworths, plans to double outlets by the end of 2009.
RPG Enterprises plans to open over 450 MusicWorld stores covering 4 million square feet by 2010.
Birla , through its Trinethra acquisition, opened around 220 stores last year alone.
Pharmaceutical Market
India's pharmaceutical industry is one of the fastest growing sectors in Indian economy with an average
annual growth rate of 11.42 percent during 2001‐2007. The industry crossed $ 6.5 billion in 2007. Indian
pharmaceutical industry has the potential to reach $ 25 billion by 2010.
Logistics is regarded as a crucial part of the pharmaceutical industry since the activities are highly time
sensitive. In addition, pharma products need temperature controlled storage and distribution.
Saurabh Nigam/ 34
Impact of Globalization
Inventory 25%
Packaging 11%
Limited physical infrastructure. India has one of the largest road networks in the world, yet less than half
of the roads are paved and less than 2000 km are express highways, a significant difference when
compared to China’s 30,000 kims. The poor condition of roads translates directly to shorter vehicle
lifespan ,which increases operating costs and reduces efficiency.
Over burdened ports. India has a long coastline, but its port system isn’t well utilized. Seventy percent of
the seaborne trade is handled by 2 of its 12 major ports, while 185 minor ports go virtually unutilized.
Non existent warehouse standards. While infrastructure covering roads, airports and seaports remain the
focus area for investment, warehousing as a facilitator for the agricultural sector has failed to keep pace
with rising farm output. There is virtually no complex distribution center set‐up, no standards for suppliers,
and little vendor compliance Unorganized trucking operations. Two‐thirds of fleets have less than five
vehicles, making it difficult for shippers to manage the plethora of carriers required to handle shipment
volumes.
Saurabh Nigam/ 37
Key Challenges
Limited technology basis. Firms don’t use technology to plan, execute or communicate logistics
operations. Only an estimated 30,000 commercial vehicles have tracking systems
Skill Gaps. The core issue is Poor image / lack of attractiveness for new recruits arising from poor working
conditions and relatively lesser attractive pay and progression incentives in turn arising from the
fragmented and unorganized nature of the industry
Benchmarking and operating efficiencies. Since logistics market is highly unorganized it brings in lot of
inefficiencies. With entry of international players in Indian logistics market, operating efficiencies and
benchmarking with best players will be key to succeed in logistics market
Though VAT (Value Added Tax) has been implemented since April 1, 2005, failure in implementation of a
uniform VAT structure across different states has let the problem persist even today
A vehicle that costs USD 30,000 pays USD 7,500 per annum in the form of various taxes, which include the
excise duty on fuel. This is why freight cost is a major component of the cost of a product in India
Saurabh Nigam/ 38
Challenges of Globalization
Look for innovative ideas like dedicated trucks, back freighting, multimodal options as an
alternative to traditional transportation
Saurabh Nigam/ 39
Challenges of Globalization
Cost competitiveness:
Service Competitiveness:
Quality Competitiveness:
Global Sourcing
Multi-location manufacturing with identical quality
Saurabh Nigam/ 40
India’s Logistics & Transport Industry
Summary
Saurabh Nigam/ 41
Barkawi Logistics Practice – Key Findings
Barkawi Logistics Practice Business Case Details
Logistics Industry in India
Logistics Value Chain
Sample Business Cases and Key KPIs
Saurabh Nigam: Profile and Background
Saurabh Nigam: Sample Engagement Deliverables
Appendix: Other supporting details
Sample Freight Process Overview and Involved Parties
LSP Strategic
Contract Contract
Freight Contract
Contracts
Negotiation
Operations
Ocean Ocean
Shipping
Carrier Booking
Instructions
Haulage
Pre-carriage Order
Carrier
Saurabh Nigam/ 43
Transportation Management and Multi-level ordering/booking
3PL
• Organizes complete shipment for customer Shipment Order FUs / Activities
• Executes pre-carriage
Shipment Order
Confirmation
Orders Main Leg by Ocean
plus import and final
Haulage to Destination
Shipment
Shipments
Request
Freight Forwarder
• Organizes on-carriage for customer Freight
• Executes ocean leg with consolidation FUs / Activities Tour
Order
Freight Order
Confirmation
Orders final
Haulage to Destination
Freight
Shipments
Request
Carrier
• Executes on-carriage of consolidated freight
Saurabh Nigam/ 44
Warehouse Management
Receiving
Yard Mgmt
Unloading
Replenishment
Unpacking
Putaway Strategies RF Technology
• Supports incentive pay
Interleaving
Inquiry
Packing
Loading
Ship Confirm
Delivery Split
Rough Workload Estimates
Printing Labels
Shipment Update
Saurabh Nigam/ 45
Warehouse Management Functions
Outbound Shipment
Inbound Shipment
Supplier
ASN RFID Other Partners / ASN BOL HUM
Stores
Warehouses
Yard Management Delivery
VAS Billing
Unload & Receive
Tracking & Tracing
Quality Control
Warehouse Monitoring
Cross Docking
Outbound Monitoring
Asset Management
Deconsolidation
Splitting Replenishment
Bundling
Rearrangement
Wave Management
Interleave Management
Slotting & Concepting
Task and Resource Management Mobile Data Entry (Barcode, Voice, RFID)
Saurabh Nigam/ 46
WMS Execution – Processes
Execution Monitoring
Warehousing
Transportation and Storage
Management
Physical Inventory
Cross Docking
Outbound
Processing Execution
Collaboration
Saurabh Nigam/ 48
Shippers face significant transportation challenges in
managing extended global supply chains
Distributor
Configure VAR
& Package
In today’s pull-based
replenishment
environment, internal
Customer
and external customers
Carriers
require granular and Distributors
real-time visibility to
shipments
Rising fuel costs and
reduce negotiation
power with carrier
consolidation pressuring
freight rates
Saurabh Nigam/ 49
Streamlined LSP Operations
Saurabh Nigam/ 50
Barkawi Logistics Practice – Key Findings
Barkawi Logistics Practice Business Case Details
Logistics Industry in India
Logistics Value Chain
Sample Business Cases and Key KPIs
Saurabh Nigam: Profile and Background
Saurabh Nigam: Sample Engagement Deliverables
Appendix: Other supporting details
XXX Estimated Annual Benefits of $66.6M – $99.7M1
and One-Time Benefits of $23.1M – $27.8M
Potential Annual Benefits Potential One Time Benefits Conservative
Conservative Estimate
Estimate
Likely
Likely Scenario
Scenario
$66.6 M $99.7 M $23.1 M $27.8 M
One-time
One-time benefit
benefit
Reduced
Reduced inventory
inventory levels
levels
through $23.1
$23.1 M
M Improved
Improved warehouse
$6.5
$6.5 M Reduced
Reduced direct
direct material
material $4.8
$4.8 M
through integrated
integrated warehouse spend
spend through
through increased
increased
planning
planning && forecasting
forecasting productivity
productivity
$27.8
$27.8 M
M $11.7
$11.7 M strategic
strategic procurement
procurement $7.2
$7.2 M
M
processes
processes (one
(one time)
time)
Reduction
Reduction in
in BD&L
BD&L duedue to
to $3.3
$3.3 M Reduced
Reduced off-contract
off-contract
Inventory
Inventory carrying
carrying cost
$4.4
$4.4 M
M indirect
$8.3
$8.3 M
cost improved
improved Warehouse
Warehouse indirect spend
spend through
through
reduction
reduction $5.3
$5.3 M
M Management
Management Efficiency
Efficiency $4.1
$4.1 M
M better
better sourcing
sourcing ,,
$10.3
compliance,
compliance, andand efficiency
efficiency $10.3 M
M
Reduced
Reduced lost
lost sales
sales through
through Reduced
Reduced transportation
transportation &
&
reduced
reduced Stock-outs,
Stock-outs, $1.6
$1.6 M
M $11.4
$11.4 M
M
logistics
logistics costs
costs through
through
reduction
reduction in
in delayed
delayed improved
improved route
route planning
planning
shipments,
shipments, and
and enhanced
enhanced $2.3
$2.3 M
M and
and optimization
optimization between
between
$14.3
customer
customer satisfaction
satisfaction Plant
Plant and
and Warehouses
Warehouses $14.3 M
Reduced
Reduced BD&L
BD&L through
through
better
$7.9
$7.9 M
M Improved
Improved transportation
better supply
supply chain
chain transportation
planning
planning and
and improved
improved planning
planning && vehicle
vehicle $6.1
$6.1 M
inventory
inventory visibility
visibility
$13.1
$13.1 M
M scheduling
scheduling FTE
FTE productivity
productivity
(excludes
(excludes FTE's
FTE's for
for store
store $8.2
Reduced
Reduced manufacturing
manufacturing delivery)
$8.2 M
M
delivery)
expenses
expenses from from better
better
production
production planning,
planning,
$1.9
$1.9 M
M XXX Validated Benefits
improved
improved inventory
inventory
visibility,
visibility, improved
improved loadload $23.1
$23.1 M
M
leveling,
leveling, and
and ability
ability to
to One-Time
One-Time Benefits
Benefits
implement
implement six six sigma $3.7
$3.7 M
M
sigma $27.8
$27.8 M
M
methodology
methodology
$0.2M
$0.2M $22.1
$22.1 M
M
Reduced
Reduced Trade
Trade Promotion
Promotion Annual
Annual Benefits
Benefits
expense
expense $0.2M
$0.2M $34.2
$34.2 M
M
Saurabh Nigam/ 52
Supporting Details for $6.5M-$11.7M Annual Benefit from
“Improved Warehouse Productivity”
Conservative
Conservative Estimate
Estimate
Value Drivers
Likely
Likely Scenario
Scenario
Improved warehouse productivity: right product at the
right place at the right time, and elimination or
Move
Move from
from daily
daily
$1.5
$1.5 M
M reduction of non-value added, high human-error
physical
physical to
to Cycle
Cycle count
count $1.7
$1.7 M
M activities
Improved
Improved warehouse
warehouse
$6.5
$6.5 M
M Improved
Improved warehouse
warehouse $2.5
$2.5 M
M 1. Replace total daily physicals with efficient cycles for nearly
productivity productivity
productivity in
in "Receiving
"Receiving
productivity $11.7 80% reduction in time spent by generally one FTE per
$11.7 M through
through Put
Put Away"
Away" process
process $5.0
$5.0 M
M
warehouse. Plus process increases accuracy.
Improved
Improved warehouse
warehouse $2.5 M
M 2. Fix 24 to 72 hour inventory recognition lag with immediate
productivity
productivity in
in "Picking
"Picking
$5.0 internal transfer or external delivery receipt matching and
through
through Shipping"
Shipping" process
process $5.0 M
M
immediate discrepancy handling. Affects dock door “data
entry” personnel also on BD&L inventory handling.
Damages and mismatches addressed immediately, to
Tangible Benefits allow manufacturing and supplier to correct inventory
levels.
Value Source Baseline Improvement % 3. Efficient system directed putaway replaces “let’s see
what’s open” time loss, plus goods are located most
Move from daily physical to $1.9M1 80-90%
effectively for reorganization and movement by date code.
Cycle count
4. Ability to system direct overnight reorg by product mix and
date code to prepare for next day’s pick. Currently not
Improved warehouse $99.5M2 2.5-5% done, except for 1 FTE “cleanup” resource assigned in
productivity in “Receiving
warehouse.
through Put-away” process
5. Link POD fill request to efficient picking strategy,
Improved warehouse $99.5M2 2.5-5% optimized truckload planning, more efficient returns and
productivity in “Picking through pick area re-placements vs “I think that’s where it is”, “yes
Shipping” process this is oldest date I think”, and “this would be a good load
strategy”.
6. Eliminate date code recognition human error- expected to
increase with number of SKU’s and collaboration partners
Assumptions:
like Campbell’s.
1. Assumes 6 hours of a FTE is required for every 40 FTEs in a warehouse
based on North Metro warehouse data
2. Assumes 95% of Production Warehouse Labor, 25% of Sales Center
Warehouse Labor, 25% of Sales Center Truck Loading, 25% of Sales
Center Contract Labor Cost. Labor used in full physical excluded
Saurabh Nigam/ 53
Transportation Spend Profile: XXX Company
Saurabh Nigam/ 54
Transportation : Closing The Performance Gap Could
Result in Significant Benefits for Company
Performance Results – Key Metrics Potential Benefits: Value of Closing the Gap
Type Metric Company Peer Group
Avg. Q1
Effectiveness On-time Delivery
Performance (in %) 96.0
96.0 89.6
89.6 97.9
97.9
Transportation
Management Process 0.2
0.2 1.6
1.6 0.4
0.4 Gap to Q1
Costs (% of spend)
Gap to Average
Below Average Between Average and First Quartile
First Quartile Outlier
Key Observations
XXX’ On-time Delivery Performance, which is an important customer facing metric, is between average and first quartile. Developing transportation
forecasting and planning capabilities and integrating it with transportation execution processes will help to improve on time delivery further
XXX’ transportation spend (% of revenue) is below average indicating scope for identifying savings by leveraging analytics tools for transportation spend
opportunity analysis
XXX shipment cycle time is between average and first quartile levels indicating a scope for integration of transportation with internal processes like
warehousing, manufacturing and finance as well as with the customers to reduce in-bound and out-bound cycle time
Saurabh Nigam/ 55
Best Practices Adoption:
Transportation Management Function Maturity
Saurabh Nigam/ 56
Performance Improvements Driven by Key Value
Drivers
4.8
4.8 Transportation Spend improvement
Transportation Spend
$ 6.2M - $ 173.3M potential to top quartile: $173.3M
(% of revenue)
10.0 4.7 2.0
58,333
58,333 Shipments delivered per load planner
Shipments Delivered
improvement potential to top quartile:
per Load Planner
9,182
9,182 49,175
49,175 158,979
158,979
NA - 172.5% 172.5%
172.5%
Below Average Between Average and First Quartile First Quartile Outlier
Saurabh Nigam/ 57
Performance Drivers: Best Practice Adoption
4 4
3.8 3.7 3.6
3.3 3.4
3 2.9 3
2.7
2.4 2.4
2.2
2
0
Transportation Sourcing Transportation Planning Transporattion Transportation Transportation Transportation Charge
Forecasting Analytics Execution and Visibility Management
Avg Coverage - Peer Group Q1 Coverage - Peer Group Company Coverage Company Importance
Saurabh Nigam/ 58
Best in Class Warehouse Management Key KPIs
Performance Results – Key Metrics (Color Coding as per Wholesale Distribution benchmarks)
Type Metric XXX Overall WSD Potential Benefits: Value of Closing the Gap
Averag Q1 Averag
e e Effectiveness: Reduce Inventory Carrying Cost ($M)
Effectiveness Order fill rate(%) 94.3%
94.0% 94.4% 99.2%
% error in lines shipped 1.5%
1.0% 4.4% 1.0%
Inventory accuracy 93.1%
99.0% 95.5% 99.4%
Effectiveness: Increase free cash flow – One-time ($M)
Inventory turns per year 4.8
4.0 8.5 18.3
Saurabh Nigam/ 59
WMS – Best Practices adoption
Saurabh Nigam/ 60
Business Value of Moving The Needle
63.1
By reducing staffing levels to average
Warehouse FTE / benchmark, at an average annual FTE cost of
50.2 $0.3M
$100M of Revenue $22.5K XXX could gain $0.3M in productivity-
related benefits
94.0%
3.0%
4.0
13% Increasing inventory turns to average levels
will reduce XXX’ working capital investment
Text
Inventory
PO Error Turns
Rate 15.16%
4.8 1.5% 15 – 20%
$4.0M
by $4M
Saurabh Nigam/ 61
Warehouse Management: Improved best practices
adoption drives value capture
Avg Q1 XXX XXX
6
Saurabh Nigam/ 62
Move the Needle – XXX vs. Peers
76.4%
Cost of Sales as 64.9
Gateway Distriparks 90.7% All Cargo
% of Revenue %
8.6%
- 19.1
Operating Margin Gateway Distriparks CONCOR
2.3% %
45
Days Sales Outstanding days 21
CONCOR 61 days All Cargo
(DSO) days
Note 1: Trailing twelve month (TTM) data has been used wherever available
Peer group included in this comparison are: Western Power & Equipment, Finning International, Toromont and United Rentals
All benefit figures are in Australian Dollars (AUD) unless specified otherwise
Source: 2006-2007 Annual and Quarterly Company Reports for peers; News Reports;
Saurabh Nigam/ 63
Key Opportunities to Improve Business Processes and
Deliver Tangible Benefits
Key Value Drivers
One source of orders, one planning system, one inventory
Full integration of planning to order management (upstream) to manufacturing
1. Supply Chain Planning (downstream) to distribution
Integration of POS Data
Reduce schedule volatility and firefighting with increased planning consistency, visibility
and accuracy
2. Demand Fulfillment & Enhance linkage between schedule, materials, etc.
Execution Increase visibility to materials and goods availability/substitution
Improve Visibility and accuracy of Available to Promise inventory
Consolidate requirements to better leverage spend
3. Sourcing &
OPPORTUNITIES
Saurabh Nigam/ 64
Transportation Management Opportunities
Order-to-Delivery cycles times have decreased 53% from ’99 to ‘04 (Source: GMA)
Decreasing cycle-times and Transportation costs increased 14.1% from ’04 to ’05 (Source: CSCMP)
rising transportation costs Import / Export growth leading to port and rail capacity constraints. Forecasted driver
expected to continue shortage of 100,000 by 2014 (Source: Global Insights) and Hours of Service (HOS) rules
will create similar situation in trucking.
Consolidation in LTL by Yellow, Fed-ex and UPS changing negotiation leverage
Saurabh Nigam/ 65
Transportation Pain Points – Global Context
Rising Freight Spend Consolidation in Less-than-Truckload (LTL) carrier base reduces the shippers potential for negotiation
due to Carrier Capacity leverage, making codified SLAs and performance tracking capabilities paramount
Constraints Reduced capacity in Truck-load (TL) freight due to national driver shortage as well as reduced capacity
in rail due to the rise in international inter-modal, can leave shippers paying significant premiums (or
risking customer service issues with delays). Without freight requirements forecasting and carrier
collaboration, you can not be assured that adequate capacity will be there to meet your needs.
Transportation Legacy facility-centric transportation system structures provide limited visibility to logistics movements
Planning Inefficiencies that can be leveraged across facilities (e.g., drop-offs, zone skips)
Lack of an effective shipment optimization analysis tool limits consolidation opportunities (e.g., Less-
than-Truckload (LTL) to Truckload (TL) consolidation)
Lack of network-wide delivery visibility limits ability to capitalize on backhaul and continuous move
transportation opportunities
Out of date product master data (e.g., weight, cube) as well as transportation master data inhibits
optimized mode selection
Lack of automated shipment tender response scoring inhibits optimized carrier selection
Limited vehicle scheduling capabilities lowers private fleet asset turns (i.e., more assets required for a
given shipment volume)
Saurabh Nigam/ 66
Transportation Pain Points – Global Context
Ineffective Customer Inability to prompt user with accurate shipment options and associated costs at time of order
Service Inability to provide delivery date estimates to customer at time of order
due to Lack of Limited visibility to outbound shipments delays creates significant customer service issues as shippers
Integration and are often last to know when a customer order is delayed
Visibility Inability to capture rail-car Car Location Messages (CLMs) limits customer service experience given lack
of order status that can be provided to customers
Manual Freight Costing Excessive freight costs are often passed on by carriers who fail to adjust surcharges as fuel prices drop
& Settlement Without accurate freight cost estimating capability (including estimation of accessorial charges and
surcharges), it is difficult to identify and correct erroneous accessorial charges
Without automated freight invoice verification, the administrative burden associated with costing and
settlement (matching costs to invoices) prevents transportation labor resources from focusing on more
value-add activities (e.g., analyzing high-volume lanes and re-bidding freight contracts)
Given global and distributed nature of fulfillment, passing freight accruals on to customer may cause
customer service issues (e.g., customer should not be responsible for cost delta if fulfilled in Penang,
Malaysia versus San Jose, CA). Need ability to charge customers differently than freight costs.
Lack of Analytics Lower profitability due to inability to capture and “tie-back” freight accruals to customer orders which
Impairs Performance inhibits total-cost-to-serve metric calculations by customer, channel and product category
Improvement Limited ability to identify and communication cross-facility best practices without network wide visibility to
Initiatives shipment performance metrics in each facility
More IT resources required to connect, transfer, map and translate operational transportation data to an
executive level transportation performance dashboard
Saurabh Nigam/ 67
Transportation Pain Points – Global Context
Excessive Lack of predictive analytics translates to more unnecessary service orders (consuming labor and spare
Maintenance Costs for parts) as well as more unscheduled down-time (limiting asset turn-over)
Transportation Assets Limited maintenance order management, guided procedures and procurement capabilities drives up
manual labor expense
Lack of procurement compliance and network-wide spares visibility drives up maintenance spend as well
as maintenance asset inventory levels
Saurabh Nigam/ 68
Barkawi Logistics Practice – Key Findings
Barkawi Logistics Practice Business Case Details
Logistics Industry in India
Logistics Value Chain
Sample Business Cases and Key KPIs
Saurabh Nigam: Profile and Background
Saurabh Nigam: Sample Engagement Deliverables
Appendix: Other supporting details
Saurabh Nigam/ 69
Saurabh Nigam: Professional Highlights in Supply Chain
Area
Key Projects Completed
Overall 8 years of experience with 7 years of experience in Customer Service, Supply Chain Planning,
Supply Chain Execution and Utilities Demand Planning areas
Saurabh Nigam/ 70
Barkawi Logistics Practice – Key Findings
Barkawi Logistics Practice Business Case Details
Logistics Industry in India
Logistics Value Chain
Sample Business Cases and Key KPIs
Saurabh Nigam: Profile and Background
Saurabh Nigam: Sample Engagement Deliverables
Appendix: Other supporting details
Saurabh Nigam/ 71
Value Engineering Assessment: Approach
Activities
Validate/ confirm Understand/ Validate findings, Present
executive validate company/ refine business preliminary XXX
alignment on BU strategy and case NABU SCM
engagement pain points through Develop high level business case to
scope, approach, targeted interviews benefit estimates SC Leadership
timeline, Develop data Team
Finalize solution
objectives and request to create a Discuss next
deliverables recommendation
business case and value steps
Identify key Analyze operational proposition
business areas of and financial data
focus and pain to estimate
points where can potential cost
help unlock savings and
business value revenue uplift
opportunities
Saurabh Nigam/ 72
Significant Participation from XXX
Identify Business Challenges, Pain Points, and Implications
Saurabh Nigam/ 73
XXX’s Goals & Objectives
Saurabh Nigam/ 74
A Unique Opportunity to Address Existing and Emerging Supply
Chain Challenges in Light of Changing Consumer Preferences
Increase Productivity and Growth through M&A has resulted in non-standardized and non-optimized
Standardize Operations operations
Poor forecasting techniques, not leveraging demand signals, and a push based
supply network results in supply chain waste and inefficiency
Lack of tools, disconnected systems, and spreadsheet based processes create
significant challenges in achieving lean operations
Limited or no visibility into the location and utilization of assets, poor project
tracking, no real time reporting, no real business intelligence, and poor call
tracking and routing
Balance Exacting Lack of planning and execution excellence preventing sharing of best practices
Execution and Continuous and continuous improvement
Improvement Variations in process compliance are preventing improvement
XXX requires a mindset shift from “do as I say” to “do better”
XXX must develop and foster a culture which embraces change and continuous
improvement, not one that resists it
Saurabh Nigam/ 75
What XXX is saying….
“XXX is a “hero system” – don’t have great core processes – but rather highly
variable performance (that is) dependent upon how dynamic/strong the leader of
the group is”
“I need procurement issues, DRP issues, and traceability issues solved now.
This is what’s killing me”
“(We need to) move to a demand driven supply network, rather than a ‘push
“
and pray’ network
Saurabh Nigam/ 76
XXX SC Discovery: Common Themes
More Pull from Customer Need at achieve a demand driven supply network
vs. Need to improve forecast accuracy, manage pull demand, and tightly control
Push from Bottling product flow.
Replenish based on true demand.
Increase use of retailer signals like POS, EDI, RFID, etc.
Increase Technology in Install RF devices and more data entry and lookup points.
Operations to Increase Lack of inventory visibility across system including private bottlers and affiliates.
Efficiency and Eliminate inefficient daily physical inventory counting.
Effectiveness Simplify numerous data entry points and many analysts and clerks who support
these complex entry points.
Standardize and Optimize Regularly identify and remove slow moving products (revenue management).
operations Need centralized planning to achieve line and budget efficiencies.
Better visibility of all maintenance projects.
Reduce BD&L of approximately $82m annual; 50% which is old stock in stores
and warehouses.
Forward traceability for bad lots and swift response to market actions.
Identify and mitigate operational risks.
Saurabh Nigam/ 77
Key Opportunities to Improve Business Processes and
Deliver Tangible Benefits
Key Value Drivers
One source of orders, one planning system, one inventory
Full integration of planning to order management (upstream) to manufacturing
1. Supply Chain Planning (downstream) to distribution
Integration of POS Data
Reduce schedule volatility and firefighting with increased planning consistency,
visibility and accuracy
2. Demand Fulfillment & Enhance linkage between schedule, materials, etc.
Execution Increase visibility to materials and goods availability/substitution
Improve Visibility and accuracy of Available to Promise inventory
Consolidate requirements to better leverage spend
3. Sourcing &
OPPORTUNITIES
4. Asset Tracking & Proactively manage, plan, and execute preventive & corrective maintenance
Utilization activities to avoid unexpected equipment failures
Optimize maintenance activities based on resource availability and qualifications
Saurabh Nigam/ 78
XXXNA Estimated Annual Benefits of $66.6M – $99.7M1 and
One-Time Benefits of $23.1M – $27.8M
Potential Annual Benefits Potential One Time Benefits Conservative
Conservative Estimate
Estimate
Likely
Likely Scenario
Scenario
$66.6 M $99.7 M $23.1 M $27.8 M
One-time
One-time benefit
benefit
Supply Chain Planning Demand Fulfillment & Execution Sourcing and Procurement
$16.0 M - $24.6 M $27.3 M - $38.3 M $13.1 M - $17.5 M
Reduced
Reduced inventory
inventory levels
levels
through $23.1
$23.1 M
M Improved
Improved warehouse
$6.5
$6.5 M
M Reduced
Reduced direct
direct material
material $4.8
$4.8 M
M
through integrated
integrated warehouse spend
spend through
through increased
increased
planning
planning && forecasting
forecasting productivity
productivity
$27.8
$27.8 M
M $11.7
$11.7 M
M strategic
strategic procurement
procurement $7.2
$7.2 M
M
processes
processes (one
(one time)
time)
Reduction
Reduction in
in BD&L
BD&L duedue to
to $3.3
$3.3 M
M Reduced
Reduced off-contract
off-contract
Inventory
Inventory carrying
carrying cost
$4.4
$4.4 M
M indirect
$8.3
$8.3 M
M
cost improved
improved Warehouse
Warehouse indirect spend
spend through
through
reduction
reduction $5.3
$5.3 M
M Management
Management Efficiency
Efficiency $4.1
$4.1 M
M better
better sourcing
sourcing ,,
$10.3
compliance,
compliance, andand efficiency
efficiency $10.3 M
M
Reduced
Reduced lost
lost sales
sales through
through Reduced
Reduced transportation
transportation &
&
reduced
reduced Stock-outs,
Stock-outs, $1.6
$1.6 M
M $11.4
$11.4 M
M
logistics
logistics costs
costs through
through
reduction
reduction in
in delayed
delayed improved
improved route
route planning
planning
shipments,
shipments, and
and enhanced
enhanced $2.3
$2.3 M
M and
and optimization
optimization between
between
$14.3
customer
customer satisfaction
satisfaction Plant
Plant and
and Warehouses
Warehouses $14.3 M
M
Reduced
Reduced BD&L
BD&L through
through
better
$7.9
$7.9 M
M Improved
Improved transportation
better supply
supply chain
chain transportation
planning
planning and
and improved
improved planning
planning && vehicle
vehicle $6.1
$6.1 M
M
inventory
inventory visibility
visibility
$13.1
$13.1 M
M scheduling
scheduling FTE
FTE productivity
productivity
(excludes
(excludes FTE's
FTE's for
for store
store $8.2
Reduced
Reduced manufacturing
manufacturing delivery)
$8.2 M
M
delivery)
expenses
expenses from from better
better
production
production planning,
planning,
$1.9
$1.9 M
M XXX Validated Benefits
improved
improved inventory
inventory
visibility,
visibility, improved
improved loadload $23.1
$23.1 M
M
leveling,
leveling, and
and ability
ability to
to One-Time
One-Time Benefits
Benefits
implement
implement six six sigma $3.7
$3.7 M
M
sigma $27.8
$27.8 M
M
methodology
methodology
$0.2M
$0.2M $22.1
$22.1 M
Reduced
Reduced Trade
Trade Promotion
Promotion Annual
Annual Benefits
Benefits
expense
expense $0.2M
$0.2M $34.2
$34.2 M
M
Saurabh Nigam/ 79
XXXNA Estimated Annual Benefits of $66.6M – $99.7M1 and
One-Time Benefits of $23.1M – $27.8M
Potential Annual Benefits1 Potential One Time Benefits Conservative
Conservative Estimate
Estimate
Likely
Likely Scenario
Scenario
$66.6 M $99.7 M $23.1 M $27.8 M
One-time
One-time benefit
benefit
1
Excludes One Time Benefits
Saurabh Nigam/ 80
Supporting Details for $6.5M-$11.7M Annual Benefit from
“Improved Warehouse Productivity”
Conservative
Conservative Estimate
Estimate
Value Drivers
Likely
Likely Scenario
Scenario
Improved warehouse productivity: right product at the
right place at the right time, and elimination or
Move
Move from
from daily
daily
$1.5 M
M reduction of non-value added, high human-error
physical
physical to
to Cycle
Cycle count
count $1.7
$1.7 M
M activities
Improved
Improved warehouse
warehouse
$6.5
$6.5 M
M Improved
Improved warehouse
warehouse $2.5
$2.5 M
productivity productivity
productivity in
in "Receiving
"Receiving 1. Replace total daily physicals with efficient cycles for nearly
productivity $11.7
$11.7 M
M through
through Put
Put Away"
Away" process
process $5.0
$5.0 M 80% reduction in time spent by generally one FTE per
warehouse. Plus process increases accuracy.
Improved
Improved warehouse
warehouse $2.5
$2.5 M
productivity
productivity in
in "Picking
"Picking 2. Fix 24 to 72 hour inventory recognition lag with immediate
through
through Shipping"
Shipping" process
process $5.0
$5.0 M internal transfer or external delivery receipt matching and
immediate discrepancy handling. Affects dock door “data
entry” personnel also on BD&L inventory handling.
Tangible Benefits Damages and mismatches addressed immediately, to
allow manufacturing and supplier to correct inventory
Value Source Baseline Improvement % levels.
3. Efficient system directed putaway replaces “let’s see
Move from daily physical to $1.9M1 80-90% what’s open” time loss, plus goods are located most
Cycle count effectively for reorganization and movement by date code.
4. Ability to system direct overnight reorg by product mix and
Improved warehouse $99.5M2 2.5-5% date code to prepare for next day’s pick. Currently not
productivity in “Receiving done, except for 1 FTE “cleanup” resource assigned in
through Put-away” process
warehouse.
Improved warehouse $99.5M2 2.5-5% 5. Link POD fill request to efficient picking strategy,
productivity in “Picking through optimized truckload planning, more efficient returns and
Shipping” process pick area re-placements vs “I think that’s where it is”, “yes
this is oldest date I think”, and “this would be a good load
strategy”.
Assumptions: 6. Eliminate date code recognition human error- expected to
1. Assumes 6 hours of a FTE is required for every 40 FTEs in a warehouse increase with number of SKU’s and collaboration partners
based on North Metro warehouse data like Campbell’s.
2. Assumes 95% of Production Warehouse Labor, 25% of Sales Center
Warehouse Labor, 25% of Sales Center Truck Loading, 25% of Sales
Center Contract Labor Cost. Labor used in full physical excluded
Saurabh Nigam/ 81
XXX Benchmark
Saurabh Nigam/ 82
XXX Benchmark
Saurabh Nigam/ 83
XXX Benchmark
Saurabh Nigam/ 84
Project SCORE Estimated Project Costs
Saurabh Nigam/ 85
Project SCORE Timeline
2007 2008
Task Nam e Start Finish Duration Jun Jul Aug Sep Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec
Integration Test 1 7/20/2007 10/4/2007 11w
Mock Conversion 2 7/24/2007 10/8/2007 11w
Mock Conversion 3 10/8/2007 11/23/2007 7w
Integration Test 2 10/29/2007 12/21/2007 8w
Integration Test 3 1/7/2008 2/22/2008 7w
Performance Test Cycle 1 11/5/2007 12/28/2007 8w
Performance Test Cycle 2 1/28/2008 2/29/2008 5w
Cutover Mock 1 12/3/2007 1/11/2008 6w
F&R Solution Validation Prep 12/31/2007 1/25/2008 4w
F&R Solution Validation 1/28/2008 2/29/2008 5w
Cutover Mock 2 1/21/2008 2/15/2008 4w
Production Cutover 2/25/2008 3/21/2008 4w
2 Store Pilot 3/24/2008 5/16/2008 8w
All Store Rollout 5/18/2008 9/26/2008 90d
Saurabh Nigam/ 86
Yearly Cost & Benefit Analysis (Likely Scenario)
ROI 182%
Payback 22 Months
Saurabh Nigam/ 87
Best in Class Warehouse Management Key KPIs
Performance Results – Key Metrics (Color Coding as per Wholesale Distribution benchmarks)
Type Metric XXX Overall WSD Potential Benefits: Value of Closing the Gap
Averag Q1 Averag
e e Effectiveness: Reduce Inventory Carrying Cost ($M)
Effectiveness Order fill rate(%) 94.3%
94.0% 94.4% 99.2%
% error in lines shipped 1.5%
1.0% 4.4% 1.0%
Inventory accuracy 93.1%
99.0% 95.5% 99.4%
Effectiveness: Increase free cash flow – One-time ($M)
Inventory turns per year 4.8
4.0 8.5 18.3
Saurabh Nigam/ 88
Barkawi Logistics Practice – Key Findings
Barkawi Logistics Practice Business Case Details
Logistics Industry in India
Logistics Value Chain
Sample Business Cases and Key KPIs
Saurabh Nigam: Profile and Background
Saurabh Nigam: Sample Engagement Deliverables
Appendix: Other supporting details
India Logistics Growth Drivers Supply Side
Saurabh Nigam/ 93
Telematics is emerging here……
Cross Industry
Radio / TV Apps
Broadcasting Public Sector
Information Insurance Crash Data
Entertainment Fleet Management DOT
Traffic Medical TREAD
OEM
Customer Service
Service Provider Traffic, Toll
Emergency Diagnostics
Assistance Prognostics
Logistics Parts catalogue
Maintenance info
OEM
Information Marketing
Brokers Marketing info
Maps Product News
News & Weather Customer info
Stock Info
Home or Dealer
Remote diagnostics
Company Office e-mail
Early failure warning
Documents
Calendar
The front end device is the conduit for data and applications delivered to and from the
remote equipment/vehicle. Complexity of the device varies depending on the
implementation
The Carrier Channel includes the wireless gateway and possibly temporary storage, and
provides the connectivity between equipment/vehicles and gateway
The gateway is a middleware component that aggregates data, content and applications
The Applications provide the functionality stakeholders seek, using content from a variety
of sources.
The content is the data source for applications or the data captured by the remote
equipment/ in-vehicle device.
Saurabh Nigam/ 95
Telematics – Market Potential in India
Saurabh Nigam/ 96
Telematics Growth Issues
Low awareness of technological application in Indian Logistics & usage of other no cost or low cost
manual alternatives.
Absence of single window interface to the end users for emergency service.
Lack of electronics component base in India resulting high import dependency and higher product
cost.
Lack of initiative in rationalizing custom duty on critical components like GPS, GPS antenna and
any kind of GPS devices.
Saurabh Nigam/ 97
Impact ………
Traffic congestion,
Vehicle-Load imbalance,
Saurabh Nigam/ 98
Suggestions
Long term strategy & formalizing agreements & policies about usage of other
country / consortium location satellites and ensuring availability of the same.
Govt. initiatives for encouraging components industries for RF, Microwave Frequency
and GPS base components.
Govt. initiatives for rationalizing custom taxation on critical components like GPS
Receivers, GPS antenna and GPS based Tracking system. This should be brought as
IT component.
Govt. initiative towards automated & centralized revenue collection & disbursement as
per state-wise, body-wise usage.
Creation of comprehensive emergency support system with Govt. & Pvt. Initiatives.
Co-ordination between road & weather surveillance agencies & creation of single
window Information platform.
Saurabh Nigam/ 99
Indian Automotive Industry Profile
The Indian automotive industry mainly consists of the Commercial Cargo /Passenger Vehicle segments &
Private Vehicle segment.
The commercial segment is fragmented in terms of ownership. The industry is characterized by the lack of
adoption of technology and any sort of Telematics systems, hence is in the absence of knowledge of its direct
and indirect benefits.
Commercial segment amounts to more than 62 Lacs vehicles that consists of 36 Lacs Cargo vehicles and 26
Lacs Commercial buses, taxies & utility vehicles.
The Private automotive segment mainly consists of 4-wheeler (57 Lacs) & 2-wheelers (414 Lacs). These
segments are growing at more than 10% p. a.
Vehicles and containers have a low degree of lading that is approximately 75%.
Telematics technological initiatives by Transport companies across the globe have revealed that by using
automotive Telematics such as Vehicle Tracking Systems and in vehicle communication system, the degree of
lading was raised from the 70% range to above 90%.