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Also in this issue
2017 event calendarLean 4.0
Transport costs
When heroes are needed No failures in emergencies:
Maintenance & repair with service excellence
Q2 / 2017 edition
Your magazine for Procurement & Logistics
32
EditorialDrozak on the spot
In the past, service technicians’ efficiencysufferedduetounderdevel-opedprocessesandalackoftranspar-ency.Whilecompanieshave increas-ingly countered this through betterplanningandtheuseof intelligentre-placement-partprovisioningsystems,service-sector productivity continuestohaveimmenseunderutilizedpoten-tial.Thisisanexcitingtheme,becauseprofitinmanycompaniesdependsontheefficiencyandproductivityoftheirserviceorganizations.
Companieshaverecentlybeenforcedtoengageinfar-reachingoptimizationwithintheirserviceorganizations,fromincident detection to on-site trouble-shooting,by theuseofnew technol-ogiessuchaspay-per-useconcepts.For instance hospitals no longerpurchase dialysis machines, but in-steadpayausagefeeper treatment.Similarly,contractsaresignedfor thetrouble-freeelevatorconveyanceofacertainnumberofpeoplepermonth.
To the extent possible, then, therectification of faults takes place be-fore systems actually malfunction.Thankstoincreasingdigitization,therearenumeroussolutions for this,suchasonlinediagnosisandfault-clearing,digital system histories that identify
possible causes of failure, and ear-ly fault recognition. This could eveninvolve a signal being sent as soonas brake linings are 80% gone, forexample, rather than only when thebrakesfail.
Servicetechniciansareprovidedwiththis information in anoptiumumway.Thanks to GPS tracking and digitaltransparency, the technicianwith theright skills is guided to the job site.During his work, the system auto-matically configures his next jobs ina logistically optimal form: Does thetechnicianhave thenecessary skills?Is the next customer logistically con-venientsoastominimizetraveltime?Doesthetechnicianhaveallnecessaryreplacementpartsintheservicevehi-cle,orcan theybe transported therein a timely fashion? For the smoothprovisioning of replacement parts, itisnecessarytohavetherightpartnersfor transport, distribution networksandrepairs.
If a malfunction nevertheless takesplace, it is ideally remedied on thefirst visit. There are numerous effec-tive solutions enabling the serviceprocess as awhole to function evenif the parts are not on site or in thevehicle.Forexample,servicevehicles
can be equipped overnight, or theneededpartscanbesuppliedthroughan automatic follow-up delivery, ororderedusing tabletsand thespecif-ic technical system’s online replace-ment-parts catalog.Themost impor-tantparallelgoalshereare to reducereactiontimesandeliminatetheneedtointerfacewithworkschedulersandinternalservicetechnicians.
The service organization is responsi-bleforthishighleveloftechnicalavail-ability,alongwithitsowndepartmentalturnover, replacement-part provision-ing strategies and service-techniciandeploymentplans.Inordertooptimizeperformance on an ongoing basis, itmustcontinuallyimplementnewsolu-tionsandtirelesslysearchforcreativepathstofurtheroptimization.Becausefromgoodservicecomestrongprofits!
Onthisnote, IwishyouasuccessfulQ2,
Dr.JacekDrozak
“From service comes profit!”Dr. Jacek Drozak, founder and CEO of Drozak Consulting
MAY 15–17 MAY 2017
“WorldProcurementCongressinLondon“ Forumforknowledgeexchangeandnetworking,
withafocusonfutureprocurementtrends
AUGUST 30–31 AUGUST 2017
“RailwayForuminBerlin“ Competitiveness2025
Themobilitysector’sinnovationagenda
OCTOBER 25–27 OCTOBER 2017
“BVLLogisticsCongressinBerlin“ Industryconferenceforlogisticsandsupply-chainissues
NOVEMBER 08–10 NOVEMBER 2017
“BMESymposiuminBerlin“ Europe‘slargestbuyers’congressforpurchasersandsupplymanagers
Drozak on the spot Save the dates: 2017 event calendar
54
Service excellenceService excellence
Ensuringstrongcustomersatisfaction,and thus long-term customer loyaltyto the company, should always be aservice organization’s focus. At thesame time, theserviceandaftermar-ket sectors are economically a verysignificantmarketformanyindustries.However, service expectations forservice providers and suppliers arecurrently undergoing a fundamentalchange.
Under the influence of increasingglobalization, and driven by thedemands of business development,the service sector is being forced toreview its organization on a continu-ousbasis.Theavailabilityof replace-ment parts and service techniciansmust be assured even in growingmarkets. Moreover, increasing digiti-zation is providing opportunities formonitoring or early fault detectionfor technical systems. However, thisonly makes sense if the service or-ganization is constituted so that thetroubleshootingprocesscanalsotakeplacepromptly.Serviceexcellence inglobally competitive, highly digitizedmarkets demands a rethinkingwithinserviceorganizations.
Diverse sectors such as medicaltechnology, telecommunications,IT, elevator engineering, and energysupplyhave incommon the fact thatmany service technicians are neces-sary in thefieldtoensurecontinuoustechnicalavailabilityoftheirproducts.In addition to the fundamental deci-sion-making criteria definedby everybusiness when buying a technicalsystem, technical availability and anassociated trouble-free service andmaintenancepolicyserveasdecisivefactors in investment decisions. The
Service Excellence Take advantage of digitization’s opportunities –
offer the best service possible
customer can be satisfied only if thefundamental requirements for techni-cal availability throughout daily oper-ations,asspecified in the investmentcontract,areguaranteed.Thevariousbusinessmodelsindifferentsectors–suchaspayperuse,leasingmodels,orprimevalueaddedintheaftermar-ket(withconsumablematerialsinclud-ed) – make it additionally clear howimportant service excellence can befor companies.Thegoals associatedwithserviceexcellenceare:
» Generationofrobustcustomersatisfaction,andthuslast-ingcustomerloyalty,throughexcellentservice
» Highdegreeofefficiencyacrosstheentireaftermarketorganization
» Optimizedoperatingconditionsforexternalsupportofthecompany’sserviceofferings
» Useofdigitizationtoenabledeliveryofbetterservicethankstogreatertransparency,ortoallowthedevelopmentofnewserviceproducts
Tobeabletofulfilltheserequirementstodayand in the future,acontinuousprocessofoptimization isnecessary.In this regard, it is crucial to providecustomers with the same level ofqualityandreliabilitybothforplannedserviceprocessesand forunplannedtroubleshootingandmaintenance.
How does this happen?
>>Onthenextpage>>
At the right time, at the right place
Digitization makes it possible: With early-fault-detection systems and the precise scheduling and deployment of replacement parts,
technicians and their equipment, malfunctions can be remedied
without downtime or even be avoided.
Increase of service technician’s productivity by more than
1 hr. / working day
76
Service excellenceService excellence
Avoiding unplanned maintenance
In order to minimize the enormousorganizational efforts needed, un-plannedmaintenancevisitsmustalsobeminimized.Thenewopportunitiesprovided by digitization and sensortechnologiesarehelpfulinthisregard.For example, a reading of elevatedpowerusebyamotorcanindicateanimpending motor malfunction, whilemeasuringcrossingdataorswitchingoperationsatswitchescan indicateahigher-than-planned degree of use.Serviceormaintenanceworkcanbeactively initiatedbeforeanunplannedsystem outage occurs. If these find-ings are combinedwith a remote di-agnosis or – to the degree possible– with remote servicing possibilities,then these fault warnings or notifi-cations can be even more efficientlyhandled.
Efficient deployment of service technicians
The deployment of service techni-cians can now be planned. In thisregard,thegoalshouldbetoincreasetechnicians’ productivity to a maxi-mum.Variousapproaches shouldbeconsideredhere,suchas:
» Reducingunproductivetravelbythe service technician
» Eliminatingmultiplevisitsbythetechnician
» Ensuringinformationonsystemhistoryanderrornotificationsisavailable
In many service organizations, ser-vice technicians must still pick upnecessary replacement parts fromdecentralized warehouses. This is a
waste of valuable productive servicecapacity by highly trained technicalworkers.Here, the state of the art isrepresentedbyprovisioningconceptsthat enable the appropriate replace-mentpartstobeloadedintheservicevehicle’s trunk overnight. Thanks tothe opportunities offered by digitiza-tion, growing pains like looking for avehicle’sparkingspotorkeymanage-mentforvehiclesarealsothingsofthepast.With the help of tools likeGPSlocation or time-limited access rights–forexample,withacodefortheser-vice vehicle – approachesuseddailyinthecar-sharingindustrycanalsobeusedforthedeliveryofneededpartsto service-vehicle trunks. Combinedwith repair kits for certain types ofmalfunctions, and return processesfor unused kit components or repairparts that canbe integratedwith thevehicle-trunk deliveries, technicians’productivity can be significantly in-creased. In this regard, a productivi-ty increaseofmore thananhourperworkdayisnotuncommon.
Optimized scheduling
With the help ofGPS location of theservice vehicle, as well as a preciseunderstanding of the service skills(suchasspecificgeneralor technicalknowledge regarding security-relatedwork), technicians can be optimallydirected using automatic schedulingtools. Troubleshooting productivitycan be further improved by sendingsystem specifics or typical solutionsto theanticipated typeofproblem tothe technician’s tablet. By using thespecific system’s replacement-partcatalog,thetechniciancanalsoorderreplacement parts directly from the
warehouse,withoutadetour throughtheworkscheduler.
Preventive, speedy & efficient – elements of service excellence
Service excellence enables speedyreaction capabilities on the part ofthe service organization, significantlyreduced outage times for technicalsystems(andthusanotableboost inqualityforcustomers),andatthesametime an increase in service techni-cians’productivity.Factorsnecessaryfor this include theuseofdigitizationopportunitiesforearlyfaultdetection,thedeploymentofremotefailure-diag-nostictools,and–formanagingtech-nicians– theuseofmodern replace-ment-part provisioning systems andanappropriatesystemforhandlingre-turns.Thefiguretotherightillustrateshowtheseelementsinteract.
Customers’specificrequirementsareaccountedforthroughtheimplemen-tation of these elements. Frameworkagreementswithexternalpartnerscanbeusedtocoverdemandpeaks,thusrounding out the service-excellencepackage.
Thomas Schmölzer, AssociatePartneratDrozakConsulting
Moderndistributionandmanagementconceptscombined withthenecessarydigitizationareafundamentalrequirement
forserviceexcellence
(Automatic) failure reporting, usually via internet
RemoteservicingAssignmentoftechnician
Overnightdeliveryofnecessaryreplacementparts
GPS-guidedscheduling(vehicle,replacementparts,
technicianstaff)
Remedyingthedefect/repair
Returnofunusedreplacementparts
Reviewoffailurereport
Figure1:Sevenkindsofwasteinserviceorganizations
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Perfect symbiosis Lean 4.0 as a driver of innovative service
and maintenance organizations
Lean 4.0Lean 4.0
Few management concepts havehad such a lasting influence onmanufacturing companies’ mindsetsand activities as Lean Management.The success of this optimization ap-proach has led its manufacturing-sector principles andmethods to beadapted for administrative functions,aswellasformaintenanceandserviceprocesses,where theyhavebecomefirmlyestablishedinmanycompanies.Nevertheless, an assessment of un-derutilizedpotentialindailyoperationsoftenshowsfurtherroomforimprove-ments in service efficiency, and thusforimprovedcustomersatisfaction.
Seven types of waste
Acriticalreviewoftheseventypesofwasteinserviceorganizationsallowsthe conclusion that considerablepotential remainseven todaywith re-gard to the traditional target dimen-sions of quality, time and costs (seeFigure1).
Giventhenewopportunitiesofferedbydigitization,thetimedimensioninpar-ticular demands deeper considera-tion.Whilehavingtherightinformationis a key aspect of improving serviceefficiency, accelerating and sharinginformationcancatalyze service-pro-vision contract processing overall.This is particularly true of processesthatinvolvethird-partyprovidersintheprovisionofservices,orwhenlogisticsproviders handle replacement-partdeliveries.
Digital & efficient: Reduce errors increase quality
In addition to reductions incontract-processing times, digitiza-tion clearly offers great opportunitiestoimproveservicequality.Consistentand IT-supported contract-manage-mentprocessesdiminish susceptibil-ity to errors, which are in large partcaused by repeated process stepsor communication failures. Digitallysupported maintenance process-es, particularly for complex technicalsystems,thushavegreatpotentialforreducingerrorsandincreasingquality.In this regard,activitiesdon’thave tobe visionary ideal solutions (such asaugmented reality). Goal-oriented,easily implemented measures canthemselvesmakeasignificantcontri-bution to increased efficiency in thetraditionalkaizensense.
Digitization is thus an accelerator fortherealizationandcontinuousimprove-mentofaleanserviceorganization.
Lean Management as an outstanding toolbox
Atthesametime,LeanManagementmethods represent an outstandingset of tools for the conception andrealization of digitally supported leanserviceprocesses.Traditional(end-to-end)value-streamanalysesareabletocapturethecurrentstatus,andenableatransparentpresentationoftheinitialsituationbasedonanevaluationoftheoverallcontractlifespan.Likewise,the
depictionofanidealstateisanequallytransparentpossibilityforgeneratingagoalorvisionthatcanbeusedasthebasis for implementing immediatelyrealizable actions, which in turn rep-resentthenecessaryprerequisitesforimplementationofthevisionarygoal.
Using as a basis its many years ofexperienceintheconception,design,and realization of lean value-addedchains, Drozak Consulting has de-veloped the necessary toolbox ofmethodologies for the optimizationof service organizations. A collec-tion of more than 100 value-addinglevers, combinedwith theuseof for-ward-looking Industry 4.0 solutions,serves as foundation for the creationof customer-tailored solutions.One starting point can be a work-shop-basedquick scan.Theexistingsituation is described using a typicalvaluestreamasanexample,withtheinclusion of the employees involved.Next,aqualitativeassessmentof thedegree of underutilized potential ismade,bothwithregardtoLeanMan-agement and digitalization. A set ofobjectives isdevelopedtogether.Theresult isanevaluationanddocumen-tationofproposedmeasuresthatbothconsiders implementation complex-ity and assesses the contribution tooptimization.
Holger Zühlke, PrincipalatDrozakConsulting
Type of waste Characteristic Lean 4.0 opportunities
Delay Delayinprovidingservicestocustomer
Delayedfaultrecognition
Delayedcommunication
Improvedcontractmanagement(contract-managementprocess)
Digitallysupportedserviceprocesses(e.g.,remotediagnostics)
Duplication Repetitionofdataprovision
Repetitionofplanningprocedures
Consistentdigitizationofcontract-managementandcontract-implementationprocesses
Unnecessary movement Replacementpartsortoolsaren’tavailableatworksite
Noone-stopcontractprocessing
Bettervisibilityofreplacement-partavailability
Integratedcontractandreplacement-partscheduling
Layoutandergonomicoptimizationforstationaryserviceprocesses(e.g.,inworkshops)
Unclear communication Uncleardescriptionofserviceneeds
Insufficientdescriptionofreplacement-partneeds
Digitallysupportedserviceprocesses(e.g.,remotediagnostics)
Digitizedreplacement-partcatalog (withdecentralizedavailability)
Incorrect inventory Out-of-stocksituations
Replacementpartsaren’tavailableattherightlocation
Big-dataanalysesofreplacement-partconsumptionandneeds
Improvementinanalysisofmeantimebetweenfailures(MTBF)
Lost opportunities withregardtocustomerloyalty
withregardtoimprovementsinunder-standingcustomerneeds
Digitalassessmentofcustomerservice-provisionsatisfaction
Errors Errorsinserviceprovision
Incorrectreplacementparts
Digitallyavailableworkplansandon-sitesupportfortechnicians
Things aren’t running smoothly? Develop the right remedy with Lean 4.0
1110
Transport costsMore than a question of negotiated rates
For many companies, transport – in the procurement context, between production locations or for outgoing goods – is not a core focus. Transport networks that have developed over time are generally non-transparent webs of inbound and outbound
transport services that are minimally coordinated and lead to significant costs, often with little overall transparency.
In order to counter rising costs, most organizations hire ostensibly low-cost service providers without carrying out
further analyses of optimization potentials.
Transport costs are complex
Transportcostsgenerallydependonthreefactors:operatingcosts,thecurrentmarket situation, andthe transport company’s profitmargin. These costs are depict-edusingadifficult-to-understandmatrix of very different rates.This lack of transparency, theincreasing complexity of globalsupply chains, rising fuel prices,ever-shorter product lifecyclesand the associated growth intransportvolumeswillinthefore-seeable future lead to further in-creasesintransportcosts.Tobesure, strong competition in thetransportsector,themarketpow-er of manufacturing companies,and skillful negotiating general-ly help to keep transport costslow, but cannot exhaust the fullpotentialinthisregard.
Transport costsTransport costs
Levers for cost reduction
Transport costs continue to ac-countforthe largestsingleshareoflogisticscosts(upto50%).Evenwith minimal investment, howev-er, experience shows that trans-port-costsavingsofbetween3%and 8% can be achieved. Thestatement thus certainly applies:“Transport costs are more thana question of negotiated rates.”By taking advantage of a varietyofleversandsynergies,transportcostscanbereducedwhilesimul-taneouslyrealizingan increase inperformance.
Thus,theissueclearlyisn’toneofhiringthecheapestpossiblecarri-er.Rather,it’sprimarilyaboutem-ploying an appropriate quantityofhigh-quality,high-performancetransport service providers withmarket-level prices and optimaltariff models. A sustainable re-duction in transportcostscan inthisregardbeachievedonlywithanintegrated,strategicandstruc-tural logistics concept that takesmultiplekeyissuesintoview.
Transport-network utilization
Inordertoachieveoptimumover-all utilization, the transport net-work should be analyzed as awhole (inbound, outbound, andempty return transport), with thegoal of monitoring goods move-ments in their entirety. With thehelp of a comprehensive trans-port strategy and an integratedtransport management style,both transparencyandtheabilityto plan transport processes canbe improved. Additionally, im-plementing consolidation pointscan produce synergies, enablingtransporttobebothreducedandmoreefficiently utilized.Addition-alincreasesincapacityutilizationand reductions in empty kilom-eters can be achieved by usingroundtripsor introducingamilk-runmodel.
Company-wide freightconsolida-tion, efficient load building, andcoordinated transport structuresalso offer significant potentialfor savings without a time-inten-sive new tender or negotiationsprocess.
Analysis of delivery terms
In large transport networks, in-dividual suppliers’ specific termsand conditions can vary sub-stantially. In this respect, famil-iar Incoterms such as deliveredat place (DAP) can still includehidden delivery-company costs.In some cases, these are diffi-cult to assign to individual costpools, and accordingly allow noinfluenceoverthetransportcosts.Bycontrast, theconsistent intro-ductionofthetraditionalEXW(ExWorks) delivery model enablesbetter transparency with regardto individual prices and procure-mentcosts,whilealsoofferingtheabilitytomanagethesupplychainactivelyandbenefitfromaddition-alsavingspotentials.
Potential of digitization
For optimal transport processesand a sustainable reduction oftransport costs, administrativeprocesses too must be consid-ered,and informationflowsmustbe coordinated with the overalltransportation concept. Underthe “Industry 4.0” catchword,digitization in the logistics sectordescribes an integrated, decen-tralized, fully networked informa-tion flow that connects suppliersandtransportcompanieswiththepurchasingenterprise.
A fusion of integrated procure-ment processes with integratedtransport processes across acommon organizational platformenablesatransparent,continuousinformationflowaswellasacloseand long-term partnership withsuppliers. A software-supportedtransportplanning,management,andcontrolprocessalongwithagapless telematics system (trackandtrace)hereoffers–inadditionto a reduction in administrativeactivities – reliable real-timedatathat sustainably supports theoptimizationoftheentirepurchas-ingandtransportprocess.
Controlling
Wheremarketsandsupplychainsareconsistently influx, the entirearray of affectedmeasuresmustberegularlyreviewedandadaptedasnecessary.Anannualauditandreviewof thecurrentstructureofexisting contract conditions andthecurrentmarketsituation,alongwith an external vendor-bench-marking process, can deliver adurableandcontinuousminimiza-tionoftransportcosts.
Clemens Wagner, ConsultantatDrozakConsulting
Preview
In our next issue:Procurement and Value Creation in Times of Economic and Political Risk
Systematic risk reduction Optimization of risk
management and value creation
Global Economic Prospects and Risks
Interview with Prof. Clemens Fuest
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