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Abstract no. 011-0268
Applying hybrid system theory to supply chain design
Volker Stich, Jan Christoph Meyer
Research Institute of Operations Management (FIR) at RWTH Aachen University
FIR at RWTH Aachen University, Pontdriesch 14/16, D-52062 Aachen
Email: [email protected]. Phone: +49 241 47705 427
POMS 20th Annual Conference
Orlando, Florida U.S.A.
May 1 to May 4, 2009
ABSTRACT
Supply Chain Management delivers a considerable amount of ideas and methods to design
the value stream. Each of these concepts may lead to significant cost reduction and higher
service levels. But the same concept does not work for different customers and their diverse
needs. Thus, a “one size fits it all” supply chain cannot lead to success. The key to overcome
this obstacle is the hybrid supply chain. This paper outlines the application of hybrid system
theory to supply chains. After a comprehensive overview of existing methods for the design of
supply chains is given, a methodology for a customer-to-customer oriented supply chain
design is presented. This approach adopts the hybrid system theory to supply chains which is
in a nutshell that hybrid systems use the advantages of its subsystems to reach a superior
result to one system alone. Concluding a case study illustrates the application of the
methodology.
I. INTRODUCTION
In modern business, satisfying customer needs is a strategic factor of success. Nevertheless,
many companies are incapable of fulfilling logistic services as they are required by the
market. In consumer goods industry for instance, this deficiency results in out-of-stock-
situations and high sales losses (GRÜN et al. 2002, p. 7ff). Insufficient availability of goods,
at the point-of-sale or in any stage of the supply chain, is caused by inadequate service levels
of the suppliers, inaccurate forecasting, lack of information exchange and unpredictable
ordering behaviour of suppliers (BUNDESVEREINIGUNG LOGISTIK 2005, p. 99).
However, the underlying reason for insufficient availability of goods is best described by an
antagonism between the desire to minimize supply chain costs by raising efficiency, and the
wish to maximize availability by increasing the agilitiy of the supply chain. This can be
derived from the diverging goals of the entities and members of the supply chain: Whereas
demand-orientated, customer-focused entities focus on high flexibility, short delivery-time
and high availability, supply-side oriented entities value primarily the minimization of
production-, transport-, purchasing- and inventory costs (STRATTON/WARBURTON 2003,
p. 184). Diverging goals may exist even in a single company (e.g. between sales, procurement
and production departments) and are prevalent between different companies that are working
together in a supply chain. The antagonism between demand- and supply-side counterparts of
a supply chain leads to significant logistical deficits.
Supply Side Demand Side
Just-In-Time ProductionKanban
Supplier Managed Inventory (SMI)
Konsignation
One-Piece-Flow
etc.
Efficient Consumer ResponseVendor Management Inventory (VMI)
Continous Replenishment (CR)
Cross Docking (CD)
Quick Response (QR)
etc.
Produrementcosts
Stock value
Productioncosts
Inventorycosts
Efficiency
RevenueFlexibility
ReadinessNever Out-of-Stock
Agility
ManufacturerSupplier Retail
Supply Side Demand Side
Just-In-Time ProductionKanban
Supplier Managed Inventory (SMI)
Konsignation
One-Piece-Flow
etc.
Efficient Consumer ResponseVendor Management Inventory (VMI)
Continous Replenishment (CR)
Cross Docking (CD)
Quick Response (QR)
etc.
Produrementcosts
Stock value
Productioncosts
Inventorycosts
Efficiency
RevenueFlexibility
ReadinessNever Out-of-Stock
AgilityRevenue
Flexibility
ReadinessNever Out-of-Stock
Agility
ManufacturerSupplier RetailManufacturerSupplier Retail
Fig. 1: Diverging goals in the supply chain
Although this antagonism is a persistent issue in praxis, to date neither industry nor science
has found adequate approaches to resolve this dilemma. Existing approaches try to solve the
problem either by implementing a more efficient asset management, or by introducing more
effective process design. They failed, for they lack any holistic contemplation of the entire
supply chain (WILDEMANN 2009, p. 1ff). Since hitherto existing approaches themselves are
focused either on the demand- or supply-side, they are unable to cover the above mentioned
antagonism (GOLDSBY et al. 2006, pp. 57ff). As an example, Just-in-time strategies
(WOMACK/JONES 2004, p. 161) address only production- or supply-oriented parts of a
supply chain, while both Efficient Consumer Response (ECR) or Category Management
(CM) (MAU 2003, p. 22ff) intend to optimize the interface between customer and
manufacturer. As a result, supply chains are often managed in a contradicting way – both in
terms of sales activities and taking into account production and procurement goals
(cp. Fig. 1). Failure of the value stream, out-of-stocks and revenue losses are the outcome.
Risk-hedging Cost Complexity Cost
Cost
Degree of Individualization
Customer-oriented
Supply Chain
„One size fits all“Supply Chain
Number ofSupply Chains
Minimal Supply Chain Cost
Risk-hedging Cost Complexity Cost
Cost
Degree of Individualization
Customer-oriented
Supply Chain
Customer-oriented
Supply Chain
„One size fits all“Supply Chain
„One size fits all“Supply Chain
Number ofSupply Chains
Number ofSupply Chains
Minimal Supply Chain Cost
Minimal Supply Chain Cost
Fig. 2: The optimal number of supply chains
To solve this dilemma, an end-to-end orientation towards the customer is required. In terms of
the marketing perspective, the extension and diversification of the assortment of goods is
understood by striving for a higher customer orientation (STEPHAN 2007, p. 3). Reverse, this
is also valid for a specification of the supply chain itself. The first step, a different design of
supply chains in different branches, is already implemented in many industrial segments, e.g.
Fast Moving Consumer Goods (FMCG) Industry is focusing on optimising their distribution,
whereas Automotive Industry continuously increases the integration of their suppliers. But
only very few companies have recognized that a diversification of the supply chain within one
single branch of business does not only lead to further reduced costs (ATKEARNEY 2004,
p. 1), but will solve the described antagonism between demand- and supply-side. Executive
managers in modern industry therefore have to take a two-fold decision: Which type of supply
chain is suitable for their customer needs, and how many supply chains are necessary, yet
affordable under economic reasons (cp. Fig. 2).
II. ESTABLISHED APPROACHES FOR SUPPLY CHAIN DESIGN
As a first approach, Fisher (FISHER 1997, p.106ff) contrasts different types of goods and
their associated demand predictabilities with their respective supply chains. On the basis of
two generic product types – functional products with high demand predictability and long life-
cycles (e.g. diapers) and innovative products with low demand predictability and short life-
cycles (e.g. cellular phones) respectively – he defines two corresponding supply chain types to
meet the distinct requirements of these product types. For functional products, the primary
goal of supply chain design is cost reduction with respect to predictability and reliability. In
contrast, innovative products require supply chains that are designed to minimize the lead
time between order and delivery. According to Fisher, these requirements result in two
distinct types of supply chains, which he names “Efficient Supply Chain” and “Responsive
Supply Chain” (FISHER 1997, p.106ff; ALICKE 2005, p. 144; CHILDERHOUSE/TOWILL
2006, p. 361f).
Christopher, Towill and Mason-Jones, based on Fisher’s suggestion, propose the “Lean
Supply Chain”, “Agile Supply Chain” and “Leagile Supply Chain” (MASON-JONES et al.
2000, p. 4061ff; CHRISTOPHER/TOWILL 2001, p. 5; AITKEN et al. 2005, p. 75f). While
the Lean Supply Chain �ocuses on cost reduction for standardized mass-products, the Agile
Supply Chain aims for high availability of goods and short lead times. Both supply chain
types are similar to the ones described by Fisher, while the Leagile Supply Chain is an
extension of the two former types (MASON-JONES et al. 2000, p. 4061ff). It is defined as a
combination of Lean and Agile Supply Chains by different authors, introducing a point-of-
decoupling (OLHAGER 2003, p. 319ff) to separate Lean (upstream) from Agile
(downstream) processes. Extended by Christopher and Towill to what they call “hybrid
strategies”, this approach is able to model parallel processes (Lean and Agile) in a single
supply chain.
All approaches that were introduced to this point are focused on the demand-side of the
supply chain. They become extended to the supply-side by Lee (LEE 2002, p. 93ff), who
considers a distinction between stable and evolving supply processes. Stable processes are
characterized by fully developed technologies and manufacturing techniques, as well as by a
reliable procurement market. On the contrary, an evolving process is not fully developed and
becomes subject to permanent change, its procurement market is limited relating to volume
and experience. Considering the supply-side, Lee yields a “Risk-Hedging” and an “Agile”
supply chain in addition to Fisher’s Efficient and Responsive supply chains. The former is
capable of pooling and sharing capacities and resources, e.g. different companies save storage
cost by pooling their stocks of certain critical goods. The Agile Supply Chain is defined
according to Christopher’s Towill’s and Mason-Jones’ Leagile Supply Chain, namely as a
combination of the Responsive and the Risk-Hedging type.
Corsten and Gabriel (CORSTEN/GABRIEL 2004, p. 245) propose another attempt to extend
Fisher’s approach, without taking Lee’s approach into account. They define four supply chain
strategies – a lean supply chain, a flexible supply chain, a fast supply chain and an aligned
supply chain. The first three types match the Lean, Leagile and Agile supply chains of
Christopher, Towill and Mason-Jones, but the aligned supply chain represents a true extension
of the concept. Designed for efficiency, the aligned supply chain is focussing on the
optimization of internal processes, unlike the lean supply chain, which tries to further
integrate suppliers into the supply chain process.
Childerhouse and Towill summarize all depicted approaches for supply chain modelling as
“market-oriented supply chains” (CHILDERHOUSE/TOWILL 2006, p. 357ff). On the basis
of Christopher and Towill (CHRISTOPHER/TOWILL 2001, p. 235ff), they establish a
“migratory model” to describe supply chain development. This model subdivides four distinct
phases, a “product oriented push”, “market oriented push”, “aggregate market pull” and
“individual consumer pull”. While Childerhouse and Towill define a high scale of integration
as a desirable goal in migratory models in general, no such goal exists with respect to market
orientation. Instead, the desirable goal is to meet the requirements of market and customer
completely. Supply chain segmentation and the design of parallel, segment-specific supply
chains according to customer and market needs is the adequate means to achieve this goal
(SCHNETZLER et al. 2006, p. 1ff).
III. SUPPLY CHAIN SEGMENTATION
Individualization of customer needs and subsequently the individualization of production and
of supply chains themselves is a 21st-century-phenomenon (CHILDERHOUSE/TOWILL
2006, p. 357ff, SCHMIDT et al. 2008, p. 841ff). To meet this challenge, a classification of
supply chains, as well as precise knowledge of customer needs, is required. Comprehensive
systems for classification of supply chains are necessary to find the appropriate answers to the
questions “How many supply chains?” and “What kind of configuration?”
(CHILDERHOUSE/TOWILL 2006, p. 357ff). However, current approaches offer basically
just very generic support to companies that are trying to configure and improve their supply
chains (SCHNETZLER et al. 2006, p. 1ff).
Originated in marketing, segmentation intends to increase the focus on the customer, while
coping with the enhancement of complexity generated by the ongoing individualization of
demands (SCHNETZLER et al. 2006, p. 4). Homogenous segments implemented in a supply
chain allow customers to be addressed in a more distinguished way (BRUHN 2007, p. 58).
Supply chain segmentation therefore proposes a “customer-to-customer orientation” and at
the same time determines the number of required supply chains. The customer-to-customer
orientation reflects the supply chain’s orientation towards the customer, whose different
buying attitudes, individual expectations towards service and variable willingness to pay
different prices (BARRATT 2004, p. 30ff) determine the end-to-end design of the supply
chain (cp. Fig. 3). Based on this individualized input, separated supply chain segments are
formed and segment-specified phenotypes are deduced, all to meet customers demands in the
best possible way.
ManufacturerSupplier RetailCustomerneeds
Customer-to-Customer Orientation
Customer characteristics
Supply Side Demand Side
Customersatisfaction
ManufacturerSupplier RetailCustomerneeds
Customer-to-Customer Orientation
Customer characteristics
Supply Side Demand Side
Customersatisfaction
Fig. 3: Customer-to-customer orientation in the supply chain
IV. IDENTIFYING HOMOGENOUS SUPPLY CHAIN SEGMENTS
Customer needs as well as the true customer characteristics must be analysed and categorized
in order to identify the significant segments of a supply chain in a customer-to-customer
sense. The deduction of these categories is based on certain attributes and their respective
values (KNOBLICH 1969, p. 143), allowing for the classification of customer needs in the
area of the conflict between agility vs. efficiency and the description of the true customer
characteristics in terms of predictability.
To accurately describe the needs and expectations of the customer, a basis of criteria is given
by the framework of “order qualifiers” and “order winners” proposed by Hill
(HILL 2000, p. 50ff). While order qualifiers describe the fulfilment of requirements that are
necessary to be competitive at all, order winners are criteria that make a difference between
competing companies. In the sense of supply chain segmentation, different criteria may be
identified as qualifiers or winners for different customers. Following, different criteria
describing the customer needs can be deduced by means of the essential target objectives in
supply chain management (cp. Fig. 4). Among these are, expected service levels, expected
delivery reliability, expected lead time, expected flexibility, price expectations and
consignment requirements. Categorization and description of these requirements can be
achieved by defining their attributes and corresponding values.
Supply Chain Performance
Assets
To-Be
As-Is
Service LevelReliabilityOrder Cycle TimeFlexibility
Production costsProcurement costsWarehousing costsInventory costs
Inventory value
Supply Chain Costs
Supply Chain Performance
Assets
To-Be
As-Is
Service LevelReliabilityOrder Cycle TimeFlexibility
Production costsProcurement costsWarehousing costsInventory costs
Inventory value
Supply Chain Costs
Fig. 4: SCM Target System (cp. MEYER, SANDER, 2007, p. 54ff)
The definition of the customer’s characteristics may result on the basis of attributes that
describe either past time relationship to the customer or are the result of an external analysis
of a first-time customer, resulting in a re-configuration or an initial configuration of the
supply chain respectively. Such attributes may be demand volatility, seasonality, impact of
trends, information exchange, order-change behaviour and sourcing-strategies.
V. SUPPLY CHAIN PHENOTYPES
These attributes and their respective values are the basis for the supply chain segmentation. In
combination, they yield a 4-fold matrix, whose quadrants represent the distinct segments of
the supply chain that has to be designed. Each segment can be allocated to a distinct supply
chain phenotype, according to customer needs and characteristics: “cost-efficient”,
“responsive”, “accurate” and “agile” (cp. Fig. 5).
Quadrant I and IV form a homogenous pattern with respect to customer needs and customer
characteristics. A predictable behaviour of the customer allows high planning accuracy and
therefore enables the most efficient design of the involved processes (quadrant I). Meeting the
demands of unpredictably acting customers requires high agility (quadrant IV). In contrast,
quadrants II and III describe a heterogeneous situation. The customer’s desire for an agile
supply chain while acting predictable, requires the highest accuracy in the planning processes,
to guarantee the required availability and flexibility (quadrant III). However, customers acting
highly unpredictable, but demanding high cost efficiency, can only be satisfied by a highly
responsive supply chain (quadrant II).
Agi
lity
Effi
cien
cyCus
tom
erN
eeds
Customer characteristics
Predictable Non-predicatable
Cost-efficient
Accurate
Responsive
Agile
I II
III IV
Agi
lity
Effi
cien
cyCus
tom
erN
eeds
Customer characteristics
Predictable Non-predicatable
Cost-efficient
Accurate
Responsive
Agile
I II
III IV
Fig. 5: Supply chain segments and supply chain phenotypes
VI. HYBRID SUPPLY CHAINS
Supply chain segmentation allows companies to classify their customers and allocate them to
the four segments described above. The corresponding supply chain phenotypes constitute the
initial point to adjust all supply chain activities. To supply customers according to their
respective requirements, it is recommendable for companies to establish four supply chains, if
their portfolio of customers is heterogeneous, or less if a more uniform type of portfolio is
present. By this approach, all customers can be satisfied, while supply chain agility and
efficiency are respected. Simultaneous operating of different supply chains, in which
customers are being allocated accordantly, is therefore the next consequential step in supply
chain management. The mentioned antagonism of a “one size fits all” approach and its
divergent goals can be resolved by introducing the described approach which is called “hybrid
supply chain”.
System: Hybrid Engine
Subsystem 1: Combustion Engine Subsystem 2: Electric Engine
Indended Purpose: Propulsion
+ High velocity+ High Range+ High Torque- Emission - Bad Energy Balance
+ Zero-Emission- Low Velocity - Low Range
+ High Velocity+ High Range+ Reduced Emission + Improved Energy Balance
System: Hybrid Engine
Subsystem 1: Combustion Engine Subsystem 2: Electric Engine
Indended Purpose: Propulsion
+ High velocity+ High Range+ High Torque- Emission - Bad Energy Balance
+ Zero-Emission- Low Velocity - Low Range
+ High Velocity+ High Range+ Reduced Emission + Improved Energy Balance
Fig. 6: Hybrid engine as an example of a hybrid system
The joint use of different supply chain phenotypes equates on the definition of a hybrid
system (BROCKE 2004, p. 13f), for which a hybrid engine is an adequate analogy
(cp. Fig. 6). The hybrid engine covers all the advantages of a single combustion engine (high
moment of torque, high final speed, high cruising range) and an electric motor (zero-emission,
both exhaust and noise) by simultaneously minimizing their disadvantages (emission and bad
energy balance of combustion, low speed and low range of electric), thus reaching a far better
performance than any of its subsystems alone. The deduced supply chain phenotypes
constitute, in analogy to the subsystems of a hybrid engine, the different “devices” of a hybrid
supply chain, that are employed according to well-defined rules and standards, that is to say,
the segmentation.
VIII. CASE STUDY
In order to proof the practicability of the shown concept of hybrid supply chains, a short case
study is illustrated. A company with more the 50.000 employees and subsidiaries in about 100
countries worldwide served different markets by a “one-size fits all”-supply chain. The
different market segments across all business units are semiconductor, assembly, aerospace,
construction, surface treatment, flexible packing, consumer goods, paper converting, coating,
tobacco, automotive, steel and coil and metal packaging. Indeed, the supply chain
performance did not meet the needs of the different market segments perfectly. The situation
of the “one-size fits all”-supply chain lead to insufficient customer satisfaction, because their
divers requirements had not been mapped to the supply chain. To resolve this obstacle, the
company decided to implement the hybrid supply chain approach.
First, the company accomplished a comprehensive analysis of each customer’s needs and
characteristics resulting in about 20 homogenous customer types across all business units.
According to the identified needs and characteristics, each customer type, and by this means
the corresponding customers, had been allocated to a supply chain segment in the described 4-
fold Matrix (cp. Fig. 7).
BUA Direct Customers S/MBUA Key Account LBUB Direct CustomersBUB DistributorsBUC Direct Customers S/MBUC Distributors ElectronicsBUC Distributors AerospaceBUD Direct Customers High MarginBUD Direct Customers Low MarginBUD Key Account High MarginBUD Key Account Low MarginBUD Distributors WholesalersBUE Direct Customers S/MBUE Key AccountBUE Distributors/MaintenanceBUF PartsBUF Loctite ProductsBUF PVCBUF MPTBUF Teroson Products
Customer characteristics
Cus
tom
er N
eeds
predictable Non-predictable
Agi
lity
Effi
cien
cy
Agile Supply Chain
Accurate Supply Chain
Responsive Supply Chain
Cost-efficient Supply Chain
BUA Direct Customers S/MBUA Key Account LBUB Direct CustomersBUB DistributorsBUC Direct Customers S/MBUC Distributors ElectronicsBUC Distributors AerospaceBUD Direct Customers High MarginBUD Direct Customers Low MarginBUD Key Account High MarginBUD Key Account Low MarginBUD Distributors WholesalersBUE Direct Customers S/MBUE Key AccountBUE Distributors/MaintenanceBUF PartsBUF Loctite ProductsBUF PVCBUF MPTBUF Teroson Products
BUA Direct Customers S/MBUA Key Account LBUB Direct CustomersBUB DistributorsBUC Direct Customers S/MBUC Distributors ElectronicsBUC Distributors AerospaceBUD Direct Customers High MarginBUD Direct Customers Low MarginBUD Key Account High MarginBUD Key Account Low MarginBUD Distributors WholesalersBUE Direct Customers S/MBUE Key AccountBUE Distributors/MaintenanceBUF PartsBUF Loctite ProductsBUF PVCBUF MPTBUF Teroson Products
Customer characteristics
Cus
tom
er N
eeds
predictable Non-predictable
Agi
lity
Effi
cien
cy
Agile Supply Chain
Accurate Supply Chain
Responsive Supply Chain
Cost-efficient Supply Chain
Customer characteristics
Cus
tom
er N
eeds
predictable Non-predictable
Agi
lity
Effi
cien
cy
Agile Supply Chain
Accurate Supply Chain
Responsive Supply Chain
Cost-efficient Supply Chain
Agile Supply Chain
Accurate Supply Chain
Responsive Supply Chain
Cost-efficient Supply Chain
Fig. 7: Allocation of the customer types to the supply chain segments
In a second step, each of the supply chain phenotypes has been detailed by standard supply
chain strategies. The “Cost-efficient Supply Chain” aims for highest capacity utilization in
production and distribution to create the cost efficiencies in the supply chain. Therefore a
combination of a make-to-order and make-to-forecast strategy has been applied. The
“Responsive Supply Chain” pursues aggressive make-to-order strategies to be responsive and
flexible to changing orders. The “Accurate Supply Chain” strives for optimized inventories by
keeping the pipeline flowing to reduce the risks of supply short-ages. Thus, a pure make-to-
stock strategy has been utilized. Finally, the Agile Supply Chain is carried out by a
combination of make-to-order and make-to-(buffer) stock strategy to be responsive, while
reducing the risks of supply short-ages.
In a third step, each supply chain phenotype has been aligned with distinct supply chain
performance levels. The essential key performance indicators of the supply chain that are
service level, reliability, order cycle time and flexibility and costs have been defined
according to the customer needs and characteristics for each supply chain segment. Thereby,
it is obvious that the “Agile Supply Chain” is subject to the highest performance level,
whereas the “Responsive Supply Chain” leads to minimal supply chain costs.
By the application of the hybrid supply chain approach the company reach a major impact on
the customer satisfaction as well as the diverging goals of the demand- and supply-side have
been aligned.
VIII. CONCLUSION
To satisfy heterogeneous customer needs, “one size fits all” supply chains turn out to be
neither effective nor efficient. The pictured antagonism between demand- and supply-side
yields significant availability problems which in turn cause eminent sales losses. This conflict
can be solved by an end-to-end orientation to the customer, while diversified requirements
and characteristics can best be met by a segmented supply chain.
Any attempt to utilize such “hybrid” supply chains for industry will first have to further
develop the approach of supply chain segmentation to substantiate the supply chain
phenotypes. According to the SCOR-model (SUPPLY CHAIN COUNCIL 2006, p. 2;
BOLSTORFF/ROSENBAUM 2003, p. 2) one has to allocate supply chain management
concepts according to the requirements of the high level processes source, make and deliver in
order to attain a detailed reference configuration for each supply chain phenotype,.
It is the aim of current research, to develop the supply chain segmentation approach further
and to build a framework for hybrid supply chains, in order to support executives in industry
in answering the question of number and configuration of supply chains and to assist them to
overcome the conflict between the market- and production-oriented sides of the supply chain.
Hybrid supply chains offer an efficient and likewise powerful way to face growing
requirements and increasing dynamics of markets, as well as the individualization of customer
needs. The final goal is therefore the extension of supply chain management by including
hybrid supply chains.
IV. ACKNOWLEDGEMENTS
The depicted research has been funded by the German Research Foundation DFG as part of
the Cluster of Excellence "Integrative Production Technology for High-Wage Countries".
More information about the Cluster of Excellence can be found on the World Wide Web
(www.production-research.de) or by contacting the authors of this publication.
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