lean supply chain management - canbyoregon.gov
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MANUFACTURING GROWTH THROUGHINNOVATION
LEAN SUPPLY CHAINMANAGEMENT
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MANUFACTURING GROWTH THROUGHINNOVATION
OMEP Organization
• Nationwide
• 60 MEP Centers
• 373 field locations
• Over 1,300 staff
• Contracting with over 2,300third party service providers
OMEP delivers best-in-class solutions.
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MANUFACTURING GROWTH THROUGHINNOVATION
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MISSION: Create a stronger Oregon economy by helpingsmall to mid-sized Oregon manufacture transform theway they do business to become more competitive in theglobal marketplace.
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Uncorrupted Information Flow
Goods & Services Process Flow
Suppliers PrimaryManufactures
SecondaryManufactures
RegionalWarehouse
Distributor Retailer Customer
SCOPE – From Suppliers to Customers
SUPPLY CHAIN MANAGEMENT SCOPE
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The goal of the lean supply chain is to
deliver products at the lowest total cost
while developing value-added processes
(as defined by the customer).
LEAN SUPPLY CHAIN MANAGEMENTGOAL
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• Minimal or no inventories in the system
• Minimal amount of warehousing space
• Optimized shipments to reduce the cost of moving inventory
• Long-term, stable supply contracts with the lowest cost
• Consistent product flow
• Single tier suppliers
• Little or no changes to production quantities
• No changes to delivery destinations
• No defects – no quality issues
IDEAL LEAN SUPPLY CHAIN
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Agile Supply Chain•Fluctuating product demand
•Short life cycle
•Short order lead time
•Make/build to order
•Inventory in parts, components orsub-assemblies
•Suppliers with flexibility, fastdelivery, high-performance designquality
•Volatile market demand.
Efficient Supply Chain•Constant product demand
•Long product life cycle
•Long fulfillment order lead time
•Make to stock products
•Inventory at finished goods level
•Suppliers provide low cost,consistent quality, and on-timedelivery
•Predictable market demand.
SUPPLY CHAINS NEED TO FIT THECOMPANY
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• What does the customer want/need?
• What is the risk aversion level of thecompany?
• What do the competitor’s offer?
• What are the supply chain cost as apercentage of sales revenue?
• How close to “Efficient” supply chaincan we move to, without sacrificingcustomer demands?
• What is the company willing to do toassure sustainable resources?
BUSINESS STRATEGY DRIVES THESUPPLY CHAIN
Vision &Strategy
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Sustainability
Env
ironm
enta
l
Soci
al
Econom
ics
Supply chain sustainability is themanagement of environmental, social andeconomic impacts, and theencouragement of good governancepractices, throughout the lifecycles ofgoods and services.
WHAT IS SUPPLY CHAINSUSTAINABILITY?
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• Is the company committed to thechanges required?
• How comfortable is the company insharing information?
• What is the tolerance for collaborationwith suppliers?
• How well do employees trustmanagement?
• Are employees willing to change roles?
• What new incentives need to be put inplace?
ALIGN THE ORGANIZATION FOR CHANGE
Vision &Strategy
ChangeManagement
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• Upper management does not stay involved
• Strategy message is not clearly defined
• Measurement are not put in place (or monitored)
• Lack of supplier trust (info)
• Employees fear of change
• Key employees not “incentivized” correctly
REASONS FOR FAILURE
ChangeManagement
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• Start with the vision (based oncustomer needs)
• Develop support policies
• Transfer the vision & strategyto the organization.
• Manage the requiredorganizational changes
• Insure key suppliersunderstand and concur.
KNOWLEDGE MAKES THE CHANGEPOSSIBLE
Vision &Strategy
ChangeManagement
KnowledgeTransfer
PolicyDeployment
12Company Vision Policy Incentives Change
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• Analyze current practices
• Analyze risk assessment
• Implement supplier qualifications
• Determine communication vehicle
• Collaborate with suppliers
• Establish production rules
• Establish measurements
DEVELOP THE SUPPLY CHAIN PROCESS
Vision &Strategy
ChangeManagement
ProcessDesign
PolicyDeploy-
ment
KnowledgeTransfer
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• Value – Define value from the perspectiveof the customer
• Responsiveness – Be able to respond tochange
• Pull – Initiate work only when requested bythe customer
• Flow – Understand the process and clear anyobstacles that don’t add value
• Perfection – Continuously refine theprocess to improve efficiency, cycle times,costs and quality
KEY PRINCIPLES OF LEAN SUPPLYCHAINS
ProcessDesign
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CHALLENGES OF LEAN SUPPLY
ProcessDesign
• Improved demand management
• Cost and waste reduction
• Process standardization
• Industry standards adoption
• Cultural change agent
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Suppliers PrimaryManufactures
SecondaryManufactures
RegionalWarehouse
Distributor Retailer Customer
Traditional supply chains amplify instability ofdemand at each stage.
PRODUCT DEMAND MANAGEMENT
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Suppliers PrimaryManufactures
SecondaryManufactures
RegionalWarehouse
Distributor Retailer Customer
IMPROVE PRODUCT DEMANDMANAGEMENT
Design the supply chain to produce as close to theend customer as possible to smooth production.
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IMPROVE PRODUCT DEMANDMANAGEMENT
Plan and produce as close to the end customer aspossible to smooth production.
“Pull vs. Push”
Suppliers PrimaryManufactures
SecondaryManufactures
RegionalWarehouse
Distributor Retailer Customer
Plan & produce
Communicate needs to all players ASAP
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Apply the right tools totransform to a Lean company.
VISUALWORKPLACE
TEAMS
QUICK SET-UP
BATCH SIZEREDUCTION
QUALITY AT THESOURCE
FLOW
PULL / KANBAN
LAYOUT
POUS
TPM
STANDARD WORK
5S
ACT
PLAN
CHECK
DO
Analysis Tools:
•Process Activity Mapping
•Supply-Chain Response Matrix
•Production-Variety Funnel
•Quality-Filter Mapping.
•Demand-Amplification
•Value-Analysis Time Profile
COST AND WASTE REDUCTIONTHROUGH LEAN
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• Improved demand management
•Cost and waste reduction “Lean”
• Process standardization
• Industry standards adoption
• Cultural change agent
THE LEAN SUPPLY FOCUS
ProcessDesign
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KnowledgeTransfer
• Leadership drives the plan
• All levels of the organization mustbe involved.
• Sustainability is the charge of topmanagement.
• Measure and post results for all tosee.
• Share results with suppliers.
• Purchasing personnel move towards“suppler manger” responsibilities.
LEADERSHIP SUSTAINS THE PLAN
Vision &Strategy
ChangeManagement
Sustainability
ProcessDesign
Leadership
PolicyDeploy-
ment
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• Inventory turns 11 – 47%
• On Time Shipments (Out) 75.2% to 97.3%
• On Time Shipments (In) 77.2% to 96.3%
• Logistics Cost 18 – 20 %
• Days Sales Outstanding (A/R) 19 – 24%
• Total Supply Chain Costs 9.6%
• Reduction in Suppliers 23% to 38%
OBTAINABLE SUPPLY CHAIN RESULTS
ProcessDesign
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• Goals and measurements
tie the strategy together
with the achieved
performances.
GOALS AND MEASUREMENTS -STRATEGY
KnowledgeTransfer
Vision &Strategy
ChangeManagement
Sustainability
Leadership
ProcessDesign
ClassPerformance
GoalDevelop.
PolicyDeploy-
ment
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Vision &Strategy
Sustainability
ProcessDesign
The measurements usually cover 4 areas:
1. Financial – Total cost of goods,manufacturing, warehousing, transportation
2. Customer - Order Fill Rate, BackorderLevels, On-Time Delivery to Customer
3. Internal Business - Adherence-To-Plan,Forecast Error , Defect Rate
4. Supplier – On-time Delivery, Sharing ofCost Reductions, Consolidation of Services
TYPICAL SUPPLY CHAINMEASUREMENTS
Leadership
GoalDevelop.
ClassPerformance
GoalDevelop.
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SUPPLY CHAIN SOFTWARE PROVIDERS
SAP Oracle
JDA Software RedPrairie
Manhattan Associates i2 Technologies
Retalix IBS
Epicor Aldata
HighJump Swisslog
CDC Software Descartes
Servigistics Infor
QAD Applied Materials
19 Sterling Commerce IFS
Vision &Strategy
ProcessDesign
Leadership
GoalDevelop.
ClassPerformance
Sustainability
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PEOPLE MAKE THE SUPPLY CHAINWORK
KnowledgeTransfer
Vision &Strategy
ChangeManagement
Sustainability
Leadership
ProcessDesign
ClassPerformance
GoalDevelop.
PolicyDeploy-
mentPeople
Trust
Mutual Respect
Integrity
Strength
Confidence
RelationshipExperience
Loyalty
Dependability
People
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Chris SchererPresident - OMEPTel: (503) [email protected]
Jim WehrsConsultantCell: (503) [email protected]
Larry PedersonBusiness Development ManagerTel: (503) [email protected]
OMEP CONTACTS – SUPPLY CHAINIMPLENTATION
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