OSCM
OSCM
OSCM
2. Operations Processes
5. Supply Chain Management : 5.1 SCM models, Key issues in SCM, 5.2
Customer service: SCM and customer service linkage, Customer
satisfaction enablers of SCM
Chain of Information & Material flow
Flow of Material, information & Finances
What is SCM …….
Supply Chain Management is a hot topic in business today. The idea is to
apply a total systems approach for managing the entire flow of information ,
materials , and services from raw materials suppliers through factories and
warehouses to the end customer. Managing this complete operation is called
as SCM.
Why SCM is hot topic today and tomorrow : There are many companies
achieving significant competitive advantage by the way they manage their
supply chain operations. Thus SCM consists of developing a strategy to
organize, control, and motivate the resources involved in the flow of services
and materials.
The unwavering focus on the customer and changing customer demands has
made the role of SCM function very critical.
Functions involved in SCM
Is one of the most important deliverable for all SCM functions. In fact the reliability of
Supply Chain depends on how successfully and consistently you are hitting the delivery
Commitments to your customers. OFP is very critical process for any manufacturing
organization , because this process has direct linkage to customer satisfaction.
It’s a responsibility of entire SCM function to manage OFP and to keep the customer
satisfied on account availability of products as per commitment. Of course as per the
committed quality norms and at the most competitive cost .
E-Commerce Supply Chain
Inventory Planning & Control
The term “Inventory” originates from the French word “inventaire” and Latin word
“Inventariom” , which implies a list of things found. The term inventory has been
defined by several authors.
The more popular of them are the term inventory includes materials- Raw , In Process,
Packaging , spares , and others stocked in order to meet an unexpected demand for
distribution in future. Another definition of Inventory : It can be used to refer to the
stock on hand at a particular time of RM’s , goods in process of Manufacture , FG’s ,
and the like tangible assets which can be seen , measured and counted ….
Yet another definition is that the term inventory includes the following categories of
items:
1) Production Inventories – Raw Materials , Parts and components which enter the
firm’s product in the production process.
2) MRO Inventories -- Maintenance , repair and operating supplies which are
consumed in the production process but which do not become part of the product
3) In-Process Inventories – Semi-Finished products found at various stages in the
production operation.
4) Finished goods Inventories – Finished Product ready for shipment.
Inventory Management
Inventory Costs : Inventories cost money. The cost factor must be considered while
taking any decision regarding inventories. Inventory cost includes ordering cost ,
carrying cost , out of stock or shortage cost and capacity cost. The details are as
follows.
• It provides a check against the loss of materials through carelessness and pilferage.
• It serves as a means of the location and disposition of inactive and obsolete items
of stores.
• Perpetual inventory values provide a consistent and reliable basis for preparing
financial statements.
The installation of a scientific inventory control system involves the use of six basic
steps :
• Selective treatment of items to establish relative importance of the items in lieu of
expenditure incurred on them per period.
Selective treatment : Selective control means variations in the method of control from
item to item based on selective basis. The criterion used for this purpose may be cost
of item , criticality , Supplier lead time , consumption pattern , procurement difficulties
, or something else. Various classifications are employed to render selective treatment
to different types of materials, where each classification emphasizes on particular
aspect. For example ABC analysis emphasizes on usage value (i.e. consumption of the
item in terms of money) , VED ( Vital-Essential- Desirable), analysis considers criticality ,
where as FSN (Fast-Slow-Non-moving) emphasizes on issue pattern of the items.
A Class items : It is usually found that hardly 5-10 % of the total items account for 70-
75% of the total money spent on materials. These items require detailed and rigid
control and need to be stocked in smaller quantities. These items are to be procured
very frequently.
B Class items : These items are generally 10-15% of the total items and represent 10-
15% of the total expenditure on the materials. These are intermediate items and control
on these items need not be as detailed & rigid as that of A class items.
C Class items : These are numerous , as many as 70-75% of total items , but they
contribute to hardly 5-10% of the total annual expenditure on materials. The
procurement policy for these items is exactly opposite to that of a class items. These
items are to procured infrequently and in sufficient quantities.
ABC Analysis
1) Prepare the total list of items and estimate their annual consumption.
3) Multiply each annual consumption by it’s unit price to get annual consumption
value for each item.
4) Arrange items in descending order of their annual usage starting with highest
annual consumption value down to the smallest value.
5) Calculate cumulative usage values and their percentages . Also express the
number of items into cumulative item percentages.
100
Percent of total annual consumption value
80
C class items
B class items
A class items
40
20
0 10 20 30 100
• Surplus items whose stocks are higher than their rate of consumption , and
• Non-moving items which are not being consumed. The last two categories are
reviewed further to decide on disposal actions to deplete the inventory.
This analysis is very useful in controlling the obsolescence, which is a major area
of concern for all organizations.
Q System & P System
Means where , the fixed quantity of materials ordered whenever the stock on hand
reaches the re-order point. The fixed quantity of material is ordered each time is
nothing but the EOQ. When the new consignment arrives , the total stock ( existing
+ new arrival ) shall be within the maximum and the minimum limits.
In this system, inventory is ordered best on fixed period. Where stock position of
each item of material is regularly reviewed. When the stock level of given item is
not sufficient to sustain the production operation until the next scheduled review ,
an order is placed replenishing the supply. The frequency of reviews varies from
firm to firm. It also varies among materials within the same firm , depending upon
the importance of the material , specific production schedules , market conditions
and so forth.
EOQ Calculations
EOQ is the level of Inventor Order of which Inventory cost is minimum. As seen earlier
under the Q system of inventory management , an order for supplies is placed when
the existing stock reaches re-order point. The relevant question now is – What should
be the size of ht order ? Buying in large quantities has it’s own problems , but of the
problems associated with bulk buying is the high ICC ( Inventory carrying cost ) Similarly
buying in small quantities reduces holding cost but adds to ordering cost. Consequently
, the materials manager is torn between a desire to keep inventories low by ordering in
small quantities and a desire to reduce the cost by buying large quantities.
EOQ Calculations
EOQ can be worked out with the help of a mathematical formula. Following
assumptions are implied in the calculations –
1) Demand for the product is constant and uniform through-out the period.
6) All demands for the product will be satisfied ( no back orders are allowed ).
EOQ Calculations
Procurement cost per period ( the product of number of orders and procurement cost
per order ) varies with the number of replenishment. The procurement cost is high if
the item is procured frequently in small lots and is less if the item is procured less
frequently and in big lots.
Inventory carrying cost ( the product of average inventory investment and the
carrying cost ) on the contrary falls when the quantity ordered per batch is small
because of low capital investment.
The two costs , therefore , are diametrically opposite to each other. The right quantity
to order will be the one that strikes at optimum balance between these two opposite
costs. When the costs have been balanced , the total cost is minimum and the
resultant quantity is termed as EOQ.
EOQ Calculations
In what economic lots should the items be purchased to minimize total cost ??
Now qo = 2 X 900 X 36
25 X 0.18
= 120 Numbers
EOQ Calculations
qo = 2 X S X Cp / Cu X i
qo = 2 X S X Cp / Ch
1. Supply Chain Management : 5.1 SCM models, Key issues
in SCM, 5.2 Customer service: SCM and customer service
linkage, Customer satisfaction enablers of SCM
SCM models
Following are some of the Supply Chain Models which are being used very
commonly now a days.
1) Integrated SC management
2) Responsive SC Management
4) Global SC Management
SCM models
Integrated Supply Chain management : It is important to recognize that one of the
most important prerequisites for successful SC management is the integration of
information flows, material flows and all the business processes within a supply chain
network. Effective & efficient management of the SC requires the integration of all
processes that go beyond purchasing & logistics activities.
1) Collaboration
2) Enterprise Extension
SCC is often defined as – two or more chain members working together to create a
competitive advantage through sharing information, making joint decisions and
sharing benefits which result from greater profitability of satisfying end customers
needs than acting alone.
Integrated Service Providers : The common name used through out industry to
describe ISP is third party & fourth party service, providers provide a range of logistics
services that includes all work necessary service customers. With the regulatory
changes in the transportation, the traditional logistics services providers started
offering warehousing & shared transportation services. Therefore, the ISPS initiated
the radical shift from single function to multifunction outsourcing.
Third Party Logistics (3PL) : The trend of using strategic partnerships in integrated
logistics has become an accepted practice in the industry. These partners are called
“Third Party service Providers” , in short 3PL firms. These services may be any one
among warehousing, transportation, Inventory management, Packaging etc. However,
the one who provides entire logistics services & offers logistics solution to customer
problem is called an “Integrator”
Fourth Party Logistics (4PL) : According to Anderson Consultants, “ 4PL assembles &
manages the resources, capabilities & technology of it’s own organization with those
of complementary service providers to deliver comprehensive supply chain solution.
The genesis of 4 PL lies in forming collaborative relationships among various logistics
service providers based on an IT backbone.
SCM models
Fourth Party Logistics(4PL) : Hence, the network arrangement can be termed as 4PL
provided if it fulfills the following requirements ……
• The integrator’s alliances are led by IT based and not asset based service providers.
The purpose of responsive supply chain is to react quickly to market demand. This
supply chain model best suites the environment in which demand predictability is low,
forecasting error is high, product life cycle is short, new product introductions are
frequent, and product variety is high.
3) Postponement
SCM models
1) Anticipatory ( or Push ) business model : In this model, the order fulfillment is
achieved from inventory of finished products. In push system, production &
distribution are based on forecasts. The problem is that forecasts are often wrong.
• Due to higher inventory of finished goods & raw materials, very high level of order
fulfillment is seen.
• Less risk of customer going away from you
• Due to push, the transportation charges get divided over the large volumes and
finally it’s an advantage towards the reduction in logistics charges
• More time is taken for changing demand patterns, higher lead times for customers
SCM models
2) Responsive ( or Pull ) business model : A pull process is activated in response to a
confirmed order from a customer. This includes make to order or JIT manufacturing
process. The production & distribution processes in a pull system are driven by actual
downstream demand and not by forecasts.
• Production & distribution are demand driven and are based on customer demand.
• In a pure pull system, the firm does not hold any inventory and only produces to
order.
• These systems are very attractive since they allow the firm to –
• A) Eliminate inventory &
• B) Generally react quickly to a changing market
Postponement deals with delaying the start of activities until time there is a real
demand, i.e. specific customer order.
Fast delivery within supply chains translates to less inventory and reduced need for
distribution facilities. Faster delivery to customer means less working capital is
required to support supply chain operations. The cash conversion cycle is a measure of
working capital efficiency.
Cash Conversion Cycle (CCC) : Is a process or a cycle where the company purchases
inventory, sells the inventory on credit as an account receivable, and then collects the
account receivable or turns it into cash. The cycle is composed of three main working
capital components: A) Days Inventory Outstanding (DIO) B) Days Sales Outstanding
(DSO) & C) Days Payable Outstanding (DPO)
Role of technology in Global Supply Chains : Technology plays following major roles in
supply chain decisions.
1) Minimizing Uncertainty: Demand & forecast variations are key pain areas for any
supply chain. Demand uncertainty can be reduced to some extent by forecasting
techniques and better communication with customers.
2) Reducing Lead times: Lead times at the stages of procurement , conversion, and
distribution can be cut down by faster modes of transport, better planning practices and
process technologies.
3) Minimizing the number of stages: The numbers of stages that goods and services
flow through add to the complexity of SCM. Unification of tasks and reducing the
number of stages make the co-ordination of decisions easier. This is the essence of
another management concept namely, Business Process Reengineering .
4) Improving Flexibility: Reducing set up or change over times in various processes and
the use of flexible manufacturing and assembly techniques improves the flexibility of
response.
5) Improving process quality: A prerequisite to effective SCM in the light of reducing
inventories and wastage is to do things RFT. This is ideal for improving process quality.
6) Minimizing variety: Variety is one of the major causes for inventory in the down
stream part of supply chains. One response is to modularize product designs so that
variety is offered in a controlled way.
Key issues in SCM
7) Managing demand: Uncertainty and anticipated variations in demand should be
dealt with by appropriate promotion and branding. This will unable a better control of
SC right from demand generation.
8) Delaying differentiation: The value addition through product differentiation should
be postponed as far as possible, so that precise customer needs can be met without
holding committed stocks in the entire chains.
9) Kitting of Supplies : In assembly systems, a major source of delay is the staging delay
where some components for assembly have to wait since matching components are not
available.
10) Focusing on “A” category : This is a well known idea from classical economics and
inventory theory, where items that account for a large part of the value or which are
critical to organization or customer, they get special attention.
11) Planning for multiple supply chains: Doing better SCM would often require different
supply chains for different customer segments based on response requirements.
12) Modifying performance measures: It becomes important to shift the performance
measurement areas in SC rather than going on with traditional measures. For example
….. In the context of a warehouse, space utilization as the primary measure of
warehouse performance , the retrieval time would be more in tune with SCM , since this
focuses on both the warehouse and down stream players.
13) Competing on service: The big opportunity in SCM for long term competitive
advantage is on the service aspects of value delivery to the customer.
SCM and customer service linkage
According to Turban : Customer service is a series of activities design to enhance the
level of customer satisfaction. i.e. The feeling that a product or service has met the
customer expectation.
SCM & Customer Service Linkages: SCM is primarily concerned with the efficient
integration of suppliers, factories, warehouses and retail outlets so that merchandise
is produced & distributed in the right quantities, to the right locations and at the right
time in a fashion that minimize total system cost. Thus customer service is an integral
component of SCM.
1) To increase sales
2) To improve customer satisfaction
3) To reduce distribution cost
4) To create value in SC
5) To retain customers.
SCM and customer service linkage
Elements of Customer Service:
2) Transaction elements : A) Lead time B) Inventory availability C) Order fill rate &
D) Order status information.
Seven rights of customer service : The concept of customer service from a supply
chain / logistics perspective is based on attainment of seven rights.
1) Right Product
2) Right Place
3) Right Cost
4) Right Customer
5) Right time
6) Right quantity
7) Right condition
Enablers of Supply Chain
Following are the cross-functional drivers of supply chain performance :
1) Facilities
2) Inventory
3) Transportation
4) Information
5) Sourcing
6) Pricing
These drivers interact with each other to determine the supply chain’s
performance in terms of responsiveness & efficiency. It is important to realise
that these drivers do not act independently but interact with each other to
determine the overall supply chain performance. Goof SC design and
operations recognizes this interaction & makes the appropriate trade-offs to
deliver the desired level of responsiveness.
The performance of the supply chain, both it’s efficiency and responsiveness,
depends upon the above six derivers.