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Transcript of ch11
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-1
Operations Operations ManagementManagement
Supply-Chain ManagementSupply-Chain ManagementChapter 11Chapter 11
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-2
OutlineOutline
Global Company Profile: Volkswagen The Strategic Importance of the Supply-
Chain Global Supply-Chain Issues
Purchasing Manufacturing Environments Service Environment Make-or-Buy Decisions
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-3
Outline - continuedOutline - continued
Supply-Chain Strategies Many Suppliers Few Suppliers Vertical Integration Keiretsu Networks Virtual Companies
Vendor Selection Vendor Evaluation Vendor Development Negotiations
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-4
Outline - continuedOutline - continued
Managing the Supply-Chain Materials Management
Distribution Systems
Benchmarking Supply-Chain Management
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-5
When you complete this chapter, you should be able to :
Identify or Define: Supply chain management Purchasing E-procurement Materials management Keiretsu Virtual companies
Describe or Explain: Purchasing strategies Approaches to negotiations
Learning ObjectivesLearning Objectives
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-6
VolkswagenVolkswagen
Brazilian plant employs 1000 workers 200 work for VW 800 work for other contractors:
Rockwell International, Cummins Engines, Deluge Automotiva, MWM, Remon and VDO, etc.
VW responsible for overall quality, marketing, research and design
VW looks to innovative supply chain to improve quality and drive down costs
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-7
Lead Figure for Chapter 11Lead Figure for Chapter 11
Graphic of VW plant, showing areas occupied by supply firms.
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-8
VolkswagenVolkswagen
Unusual elements: VW is buying not only materials, but also the labor
and related services Suppliers are integrated tightly into VW’s own
network, right down to assembly work in the plant
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-9
Planning, organizing, directing, & controlling flows of materials Begins with raw materials Continues through internal operations Ends with distribution of finished goods
Involves everyone in supply-chain Example: Your supplier’s supplier
Objective: Maximize value & lower waste
Supply-Chain ManagementSupply-Chain Management
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-10
Consumer
Retailer
Manufacturing
Material Flow
VISA®
Credit Flow
Supplier
Supplier Wholesaler
Retailer
CashFlow
OrderFlowSchedules
The Supply-ChainThe Supply-Chain
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-11
The Supply ChainThe Supply Chain
Supplier
Supplier
Supplier
Inventory
Inventory
Distributor
Inventory Inventory
Manufacturer
Customer
Customer
Customer
Market research datascheduling information
Engineering and design dataOrder flow and cash flow
Ideas and design to satisfy end customer
Material flowCredit flow
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-12
11%
31%
58%
Material
Dir Wages
Other
71%
16%13% COGS
Payroll
Other
83%
9%8%COGS
Payroll
Other
ManufacturingManufacturing
WholesaleWholesale
RetailRetail
Material Costs inMaterial Costs in Supply-Chain Supply-Chain
Source: U.S. Department of Commerce, Bureau of Census, 1987 Census of Manufacturers: General Summary of Retail Trade (Washington, D.C.: Government Printing Office, 1991)
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-13
Supply-Chain Support for Overall Supply-Chain Support for Overall StrategyStrategy
Supplier’sgoal
Primary Selection Criteria
Supply demand at lowest possible cost
Select primarily for cost
Low CostRespond quickly to changing requirements and demand to minimize stockouts
Select primarily for capacity, speed, and flexibility
ResponseShare market research; jointly develop products and options
Select primarily for product development skills
Differentiation
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-14
Supply-Chain Support for Overall Supply-Chain Support for Overall Strategy - continuedStrategy - continued
Process Characteristics
Maintain high average utilization
Low CostInvest in excess capacity and flexible processes
ResponseModular processes to lend themselves to mass customization
Inventory Characteristics
Minimize inventory throughout the chain to hold down costs
Develop responsive system, with buffer stocks positioned to ensure supply
Minimize inventory in the chain to avoid obsolescence
Differentiation
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-15
Supply-Chain Support for Overall Supply-Chain Support for Overall Strategy - continuedStrategy - continued
Lead-timeCharacteristics
Shorten lead-time as long as it does not increase costs
Low CostInvest aggressively to reduce production lead-time
ResponseInvest aggressively to reduce development lead-time
Differentiation
Product-design Characteristics
Maximize performance and minimize cost
Use product designs that lead to low set-up time and rapid production ramp-up
Use modular design to postpone product differentiation for as long as possible
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-16
Global Supply-Chain IssuesGlobal Supply-Chain Issues
Supply chains in a global environment must be: flexible enough to react to sudden changes in parts
availability, distribution, or shipping channels, import duties, and currency rates
able to use the latest computer and transmission technologies to manage the shipment of parts in and finished products out
staffed with local specialists to handle duties, trade, freight, customs and political issues
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-17
Acquisition of goods & services Activities
Help decide whether to make or buy Identify sources of supply Select suppliers & negotiate contracts Control vendor performance
Importance Major cost center Affects quality of final product
PurchasingPurchasing
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-18
Purchasing Costs as a Percent of Purchasing Costs as a Percent of SalesSales
All industry Automobile Food Lumber Paper Petroleum Transportation
52% 61% 60% 61% 55% 74% 63%
Industry Percent of Sales
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-19
Dollars of Additional Sales Needed to Dollars of Additional Sales Needed to Equal 1$ Saved Through PurchasingEqual 1$ Saved Through Purchasing
Percent of Sales Spent for Purchases
Firm'sPercentNetProfit
30% 40% 50% 60% 70% 80% 90%
2 $2.78 $3.23 $3.85 $4.76 $6.25 $9.09 $16.67
4 $2.70 $3.13 $3.70 $4.55 $5.88 $8.33 $14.29
6 $2.63 $3.03 $3.57 $4.35 $5.56 $7.69 $12.50
8 $2.56 $2.94 $3.45 $4.17 $5.26 $7.14 $11.11
10 $2.50 $2.86 $3.33 $4.00 $5.00 $6.67 $10.11
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-20
Objectives of the Purchasing Objectives of the Purchasing FunctionFunction
Help identify the products and services that can be best obtained externally; and
Develop, evaluate, and determine the best supplier, price, and delivery for those products and services
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-21
The Purchasing FocusThe Purchasing Focus
Materials Management-High transportation cost-High inventory costs
Supply Management-High costs-Scarcity: national or
international
Source Management-Unique items-Custom-made items-High technology items
PurchasingManagement-Commodity items-Standard products
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-22
ReceivingDock
PurchaseOrder
PackingList
OrderProcessing
Invoice
Receivables Report
Check Accounts Receivable
Accounts Payable
MailReconcile
CustomerCustomer SupplierSupplier
Traditional Purchasing ProcessTraditional Purchasing Process
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-23
Purchasing TechniquesPurchasing Techniques
Drop shipping and special packaging Blanket orders Invoiceless purchasing Electronic ordering and funds transfer Electronic data interchange (EDI) Stockless purchasing Standardization
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-24
Make/Buy ConsiderationsMake/Buy Considerations
lower production cost unsuitable suppliers assure adequate supply utilize surplus labor and make a
marginal contribution obtain desired quantity remove supplier collusion obtain a unique item that would
entail a prohibitive commitment from the supplier
lower acquisition cost preserve supplier
commitment obtain technical or
management ability inadequate capacity reduce inventory costs ensure flexibility and
alternate source of supply reciprocity
Reasons for Making Reasons for Buying
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-25
Make/Buy ConsiderationsMake/Buy Considerations
maintain organizational talent protect proprietary design or
quality increase/maintain size of
company
item is protected by patent or trade secret
frees management to deal with its primary business
Reasons for Making Reasons for Buying
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-26
Plans to help achieve company mission Affect long-term competitive position Strategic options
Many suppliers Few suppliers Keiretsu network Vertical integration Virtual company Plan
© 1995 Corel Corp.
Purchasing StrategiesPurchasing Strategies
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-27
Supply-Chain StrategiesSupply-Chain Strategies Negotiate with many suppliers; play one supplier against
another Develop long-term “partnering” arrangements with a few
suppliers who will work with you to satisfy the end customer
Vertically integrate; buy the actual supplier Keiretsu - have your suppliers become part of a company
coalition Create a virtual company that uses suppliers on an as-
needed basis.
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-28
Many sources per item Adversarial relationship Short-term Little openness Negotiated, sporadic PO’s High prices Infrequent, large lots Delivery to receiving dock
© 1995 Corel Corp.
Many Suppliers StrategyMany Suppliers Strategy
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-29
1 or few sources per item Partnership (JIT) Long-term, stable On-site audits & visits Exclusive contracts Low prices (large orders) Frequent, small lots Delivery to point of use
© 1995 Corel Corp.
Few Suppliers StrategyFew Suppliers Strategy
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-30
Daimler Chrysler’s Supplier Cost Daimler Chrysler’s Supplier Cost Reduction EffortReduction Effort
Supplier Suggestion Model SavingsRockwell Use passenger car door
locks on trucksDodgetrucks
$280,000
Rockwell Simplify design/substitutematerials on manualwindow system
Various $300,000
3M Change tooling for wood-grain panels to allow threefrom one die instead of two
Caravan,Voyager
$1,500,000
Trico Change wiper-bladeformulation
Various $140,000
Leslie MetalArts
Exterior lighting suggestions Various $1,500,000
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-31
Purchasers Ties Themselves to Purchasers Ties Themselves to SuppliersSuppliers
TacticTactic 1. Reduce total number of
suppliers Certify suppliers Ask for JIT delivery from
key suppliers Involve key suppliers in
new product design Develop software linkages
to suppliers
ResultsResults Average 20% reduction in 5 years Almost 40% of all companies
surveyed were themselves currently certified
About 60% ask for this About 54% do this Almost 80% claim to do this About 50% claim this; about 15%
more than have EDI links to suppliers
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-32
Raw Material(Suppliers)
BackwardBackwardIntegrationIntegration
CurrentCurrentTransformationTransformation
ForwardForwardIntegrationIntegration
Finished GoodsFinished Goods(Customers)(Customers)
Ability to produce goods previously purchased Setup operations Buy supplier
Make-buy issue Major financial
commitment Hard to do all things well
Vertical Integration StrategyVertical Integration Strategy
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-33
Forms of Vertical IntegrationForms of Vertical Integration
Iron Ore
Steel
Automobiles
DistributionSystem
Dealers
Silicon
IntegratedCircuits
Circuit Boards
ComputersWatches
Calculators
Farming
Flour Milling
Raw Material(Suppliers)
BackwardIntegration
CurrentTransformation
ForwardIntegration
Finished Goods(Customers)
Baked Goods
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-34
Japanese word for ‘affiliated chain’ System of mutual alliances and
cross-ownership Company stock is held by allied firms
Lowers need for short-term profits
Links manufacturers, suppliers, distributors, & lenders ‘Partnerships’ extend across entire supply chain
Keiretsu Network StrategyKeiretsu Network Strategy
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-35
© 1995 Corel Corp.
Virtual Company StrategyVirtual Company Strategy
Network of independent companies Linked by technology
PC’s, faxes, Internet etc.
Each contributes core competencies Typically provide services
Payroll, editing, designing
May be long or short-term Usually, only until opportunity is met
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-36
Vendor evaluation Identifying & selecting potential vendors
Vendor development Integrating buyer & supplier
Example: Electronic data exchange
Negotiations Results in contract Specifies period of agreement, price, delivery terms etc.
Vendor Selection StepsVendor Selection Steps
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-37
Vendor Selection Rating FormVendor Selection Rating Form
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-38
Company Financial stability Management Location
Product Quality Price
Service Delivery on time Condition on arrival Technical support Training
Supplier Selection CriteriaSupplier Selection Criteria
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-39
Negotiation StrategiesNegotiation Strategies
Three types: cost-based price model - supplier opens its books to
purchaser; price based upon fixed cost plus escalation clause for materials and labor
market-based price model - published price or index competitive bidding - potential suppliers bid for contract
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-40
Managing the Supply-ChainManaging the Supply-Chain
Options: Postponement Channel assembly Drop shipping Blanket orders Invoiceless purchasing Electronic ordering and funds transfer Stockless purchasing Standardization Internet purchasing (e-procurement)
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-41
Managing the Supply-Chain - Managing the Supply-Chain - Other OptionsOther Options
Establishing lines of credit for suppliers Reducing bank “float” Coordinating production and shipping
schedules with suppliers and distributors Sharing market research Making optimal use of warehouse space
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-42
Materials ManagementMaterials Management
Integrates all materials functions Purchasing Inventory management Production control Inbound traffic Warehousing and stores Incoming quality control
Objective: Efficient, low cost operations
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-43
Goods Movement OptionsGoods Movement Options
Trucking Railways Airfreight Waterways Pipelines
PowerPoint presentation to accompany Operations Management, 6E (Heizer & Render)
© 2001 by Prentice Hall, Inc., Upper Saddle River, N.J. 0745811-44
Supply-Chain Performance Supply-Chain Performance ComparedCompared
Number of suppliers perpurchasing agent
34 5
Purchasing costs as percent ofpurchases
3.3% 0.8%
Lead time (weeks) 15 8
Time spent in placing order 42 minutes 15 minutes
Percentage of late deliveries 33% 2%
Percentage of rejected material 1.5% .0001%
Number of shortages per year 400 4
Typical FirmsBenchmark
Firms