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What is the role of inventory
• Who is the customer?
• What are your company strategies?
• What are your company goals?
How does this change as you move along the chain?
Why do we have inventories?• Customers’ unreliable forecasts
• Our unreliable forecast
• Poor planning
• Poor inventory control
• Poor internal quality
• Unreliable suppliers and transportation
• Excessive supplier lead times, and poor quality
• Poor or unexpected maintenance
• Transportation opportunity
How might these impact your logistical system?
What is your strategic objective in holding inventory
• To facilitate economies of scale
• To aid in smoothing S & D
• To provide protection from uncertain demand
• To secure raw materials
• To hide problems created in other areas
Are you better off holding inventory or dealing directly with the root cause of the problem you are holding the inventory against?
Why are you holding the inventory?
Can you be successful?
Factors that influence inventory decisions
• Value• Demand & Supply Pattern• Availability• Product type• Criticality• Space• Cost• Transportation, in and out
Types of inventory
• Normal – certain times
• Safety Stock – uncertain times JIC
• In-transit
• Speculative
• Seasonal
• Dead
Inventory management objectives
• What to order?
• How much to order each time?
• How frequently to order?
• How does it serve the customer?
You need a management philosophy that’s strikes a balance between cost and customer service
Who is your customer??????
What you need to keep it visible
• Tracking and tracing• Summary and detailed reports• Notification of failure and potential interruptions• Communication
You need good data from all links!!
Where and how do you get it?
Benefits to keeping inventory visible• Increase customer service
• Decrease cost of sales
• Improve relations
• Ability to be proactive
• Improve performance of your Supply Chain partners
• Improve your bottom line
Create an advantage
In order to properly meet your objectives you must know the
cost!
Carrying costOrdering costStock-out cost
Transportation cost
As in any part of your business, you must know the cost of your inventory decisions!
Inventory Carrying Costs
• Cost of Capital– Lost Opportunity Cost– Borrowing Costs
• Inventory Labor– Wages – Fringe Benefits
• Capital Investments– Building– Material Handling Equipment– Types of Storage
Inventory Carrying Costs
• Variable Costs– Heat and Light– Insurance– Shrinkage and Obsolescence
• Tracking Costs– Computer Time & Data Entry
Signs of Trouble
• Loss of customers• Increasing number of back-orders• Stable number of back-orders with a
growing investment in inventory• Periodic lack of storage space• Deteriorating relationships with channel
members
How do you recognize them?
What can you do to fix it?
• Gain commitment from the top• Improve the information system• Examine other logistical activities• Work on improving your forecasting• Rank your inventory in some manner• Incorporate useful tools—MRP,DRP,JIC
and JIT– remember these are only tools
Remember the total cost view of the system!
Packaging or Packaging?What is your objective in packaging?
Type of product
What is the role of packaging for your product?
To Protect
To Facilitate Handling
Customer Service
Security
What is it for your project?
Packaging Trade-offs
Cost vs. Level of protectionPackaging vs. Transportation cost
Cost vs. Level of security
Mode Choice
From which point of view?At what point in the chain?
Packaging and Global Logistics• Varied conditions
– Handling, environment• Country specific packaging
– Industrial, consumer, regulatory• Degree of stability
– Safety• Degree of intermodality
– Ease of transit
• Security• Information
Which degree of packaging?
WarehousingAn integral function in the world of Global Logistics
Distribution
Sourcing
Processing
Reverse logistics
Warehousing
• Functions of Warehouses—Where in the chain?– Receiving and sorting– Storage– Consolidation– Product Mixing– Cross Dock Sorting– Order Processing– Postponement
What is the role of Warehousing?• How does this function fit into your
business model?• What does it do for you in your global
logistics activities?• What are the trade-offs?• Not a place to hide your problems!
Can it provide you with a sustainable competitive advantage???
How does it fit the system?
Warehouse Issues
• Transportation fit• Demand Level• Demand Stability, Seasonality• Need for Control• Numbers, Locations• Layout• Stocking Plans• Automation and Material Handling• Security• Standardization
It’s all about the movement!What is the function of your
warehouse(s)?
Gathering
Breakdown
Multifunctional
Principles of Warehouse Layout
• One Story Design• Move Goods in Straight Line• Efficient Material Handling Equip.• Efficient Storage Plan
– Fast Movers Up Front– Complementary Products Together– Minimize Mispicks
• Minimize Aisle Space– NEVER Dead End Aisles
• Use Full Cube of Building
Thoughts to remember
Do not forget the systems approach! If you tweak one part of the equation it will have an affect
on the others.
Thoughts cont.
Changes often require the cooperation of channel partners
The influence of country specificity
Where to locate your Warehouse?
• What are the needs of your customers?• What are your needs and the role of this facility?• What cost are involved and what are your
limitations? Look to the future!
To centralize or not to centralize? That is the question!
What do you do when one of your largest customers asks you to invest in their new warehouse facility?
Site selectionHow many and what size to have?
Where should they be located?
How do they best fit the system?
Allocation of customer demand and vendor output
What impact will these site have on entire system?
Infrastructure/labor/environment/local trends/customers/etc.
Impact of warehouse location
• Inventory– Safety stock– Lead times and variance!!!!!
• Customer service– Order cycle times– Product availability– Variability of demand
Who owns and operates your Warehouse?
Management must decide what resources they have to work with and the best way to allocate them
Cost/benefit
of
Private vs. Public vs. Contract
Trade-offs
Customer Service
Design
Control
Commitment
Initial investment
Flexibility
Country specific
Shared information
Local knowledge
Extras
Operational cost
Exit strategy
Definition of cost
Education
Carrier relations
What is your strategy?
Is this function outsourced or performed in-house?
Cost/control/additional services/duration
Look to the future, what are the trends?
Global warehousing issues
• Who has the power?
• What trade-offs will be made?
• One approach or multiple?
Size–level of security—climate control—transport access—ownership—labor—location—number—areas of responsibility
Facility designEfficient movement of goods
Inventory efficiencies and storage cost
Degree of customer service
Degree of redundancy
Manual or automated systems
Degree of current and future constraints, an eye to the future
Safety
Manual Warehouse
• Work best with demand extremes• Very flexible system—Humans
?Wages/inaccurate placement/record keeping/damage/wrong pick/other human resource issues
Automated Warehouses
Company or industry specific
Degree of standardization
Country specific issues
Degree of stability
Automation systems
Lift trucks
AS/RS
Horizontal movement
Loading/unloading
Sorting/screening
Item picking
Stationary robots
Robot vehicles
Activities automatedHorizontal movementStorage and retrieval
Scanning and updatingItem picking
Warehouse transportationCargo handling
PalletizingDe-palletizingInspections
Manual vs. Automated
• Cost• Retraining• Equipment reliability• Software• Systems integration• System flexibility
Overall system vs. country specific items
Helping you decideCharacteristics of goods handled
Desired through-put rates
Building shape and size
Labor availability
Cost
Ability to upgrade/redundancy
What is the right mix?
Benefits of automation
• Product handling• Information management• Tracking• Inventory management
“Meet the needs of the customer while supporting the process”