Supply chain
A Tompkins Associates Webcast April 23, 2002 www.tompkinsinc.com
Webcast Panel
Jim Tompkins President Tompkins Associates
John Spain Partner Tompkins Associates
Jim Lane Principal Tompkins Associates
Ralph Cox Principal Tompkins Associates
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Six Levels of Supply Chain
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Polling Question
Where doesyour company fall on the Six Levels of Supply Chain Excellence scale? 1. Business As Usual 2. Link Excellence 3. Visibility 4. Collaboration 5. Synthesis 6. Velocity
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Technology View of Supply Chain Excellence
ORDER MANAGEMENT INVENTORY & REPLENISHMENT PLANNING DEMAND MANAGEMENT DISTRIBUTION
WEB INTERFACE – CUSTOMER COLLABORATION
PROCUREMENT
PRODUCT SPECIFICATIONS
QUOTATIONS &SUPPLIER MANAGEMENT
MANUFACTURING
MES
WEB INTERFACE – SUPPLIER COLLABORATION
PURCHASING
WMS
TMS
WEB INTERFACE - CARRIER COLLABORATION
INVENTORY/ REPLENISHMENT PLANNING
MULTI-CHANNEL, MULTILOCATION ORDER RELEASE
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Objectives
§ Past demand planning and inventory management practices § Current realities and competitive needs § Inadequacies of certain practices § Thesolution—Supply Chain Synthesis § Results for you and your partners
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Demand Planning and Inventory Management
Characteristics
§ The set of processes and systems that support determination of the quantity and timing of inventory levels to meet anticipated customer demand § Requires an estimate of future demand
– Estimate of demand based upon simple math to advanced statistics over aperiod of time
§ While minimizing
– Inventory holding cost – Transactional cost
§ And maximizing
– Product availability – Customer satisfaction
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Characteristics of Inventory
§ A financial investment and asset that should be minimized § Made to serve customer’s needs
– Ultimate customer – Intermediate customer—manufacturing, distributors, etc.
§ Serves as a “buffer” betweenmanufacturing/vendor and customers § Consists of cycle stock and safety stock § Requires storage facilities (owned, leased, etc.) § Subject to risk (damage, loss, obsolescence, theft and deterioration)
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Components of Inventory
§ Cycle stock
– Inventory for routine consumption – Level dictated by average demand, lead-times, transaction costs and inventory carrying cost – Goal is to minimize costwhile providing adequate inventory between re-supply points
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Components of Inventory
HIGH
ANNUAL COST
TOTAL
INVENTORY HOLDING COST
TRANSACTION COST LOW
SMALL
THEORETICAL
OPTIMUM
LARGE
ECONOMIC ORDER QUANTITY
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Components of Inventory
§ Safety stock
– Result of variability in demand and lead times – Intended to provide inventory coverage during lead-timeif demand is above average or lead-time is greater than average – Level dictated by extent of variability and established customer service levels – Goal is to ensure customer satisfaction and reduce chance of stock-outs
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Components of Inventory
NO DEMAND
ON-HAND INVENTORY (units)
RE-ORDER POINT LOWER SHORT -TERM DEMAND RATES THAN ANTICIPATED UNIFORM DEMAND RATE ON WHICH RE-ORDERPOINT IS BASED HIGHER SHORT -TERM DEMAND RATE THAN ANTICIPATED INFINITE DEMAND "OUT OF STOCK" ZERO CONDITION
SAFETY STOCK
ACQUISITION LEAD TIME (periods)
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“Ideal” Fixed OQ Inventory Levels
140
120
100
On-Hand Inventory
80
60
40
20
0
Time
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Cycle and Safety Stock
Calculation of cycle and safety stock is adequate in predictable environments
§Accurate knowledge of transaction and inventory holding cost § Historical demand data is a good proxy for future demand § Historical product acquisition performance is a good estimate of future performance § Demand and acquisition lead-times are relatively consistent § Longer product life cycles § Limited or predictable promotional activity
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Demand and Lead Time Predictability
Keys to...
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