Showing posts with label suppliers. Show all posts
Showing posts with label suppliers. Show all posts

Monday, May 3, 2010

Supply Chain Management: Misunderstood & Misapplied

Like so many excellent concepts in business over the years, supply chain management (SCM) will probably never live up to its potential.  Too many people are unable to broaden their understanding beyond basic procurement and move toward a more systems approach required to truly optimize a company's supply chain.

What is Supply Chain Management?

The American Production & Inventory Control Society (APICS) defines supply chain management as the design, planning, execution, control, and monitoring of supply chain activities with the objective of creating net value, building a competitive infrastructure, leveraging worldwide logistics, synchronizing supply with demand, and measuring performance globally.  This definition inherently assumes that a systems thinking approach is necessary to be successful.

The suppliers that provide materials, products, and services to a company should be managed and optimized just as if they were internal to the operation.  Since they represent the starting point for a company's operation, they potentially affect everything throughout the value stream and ultimately what is provided to the customer.

To be truly effective, SCM should focus on improving quality, cycle times, and total costs in dealings with suppliers.  In theory, the process should involve understanding and optimizing the entire value chain from the very first level suppliers (those in which the company may never deal with directly) to the end customer.  Since it can be overwhelming to fully understand and take the time to build relationships with a lengthy supply chain, a more practical application of SCM involves working with a company's first tier suppliers and customers.

The way that SCM is approached in most companies, however, is to solely focus on negotiations with first tier suppliers on price and payment terms, which have very little, if any, effect on quality and cycle times, and only barely addresses the subject of total costs.

Total Costs

The total cost of dealing with suppliers involves so much more than price and payment terms.  Far too often, though, companies - even those that claim they follow an SCM approach - focus only on these aspects of the relationship while virtually ignoring the other factors that can have a much greater effect on costs (see table below).



Improving the total costs associated with the supply chain involves:
  • building close relationships with suppliers (based on trust, mutual benefit, and clear communications);
  • continually working on the factors that reduce total cost (see above table);
  • understanding and optimizing the systems of logistics for products and services procured (inbound) as well as those provided to customers (outbound) that are consistent with the company's operational and marketing strategy;
  • working with customers to understand how the supply chain affects their operations.
Once the supply chain strategy is developed, implementation begins initially with the first tier and slowly and continually expands to cover more of the supply chain.  How much of the chain depends on many factors, including the size and complexity of the supply chain and how much of it can be effectively managed.

A Generalist Approach

The topic of SCM is far too complex to adequately cover in a relatively short blog post.  The point is, though, that effective supply chain management involves so much more than negotiating price and payment terms with key suppliers.  It requires developing close relationships with customers to understand how the supply chain contributes to their needs, and systematically implementing improvements throughout the system to reduced waste and improve performance.  Those directing an organization's SCM efforts need to be systems thinkers who are much more adept at leading improvement efforts than negotiating contracts with individual suppliers.

Wednesday, December 30, 2009

World Class Suppliers Need World Class Customers

As part of their effort to slash the cost of auto parts by 30% over the next three years, Toyota met with its suppliers last week to enlist their help in the process. Based on their reputation for dealing with suppliers, I'm guessing that Toyota will approach the process in a much different manner than most companies, and the process will be very successful.

Instead of squeezing suppliers by beating down prices and lengthening payment terms, companies like Toyota work with suppliers to find improvements in designs and processes that lead to real and sustainable cost reductions. When approached in this manner, the supplier and customer benefit from the process and the savings result in strengthening, rather than weakening, the supplier.

Two Glaring (and Common) Examples

I once worked with a Fortune 500 company that issued a policy for its divisions to lengthen payment terms to all suppliers. Based on the formula, the new policy could result in payment to a supplier being delayed by up to 90 days after receipt of the product or service.

Procurement professionals at a particular division for the company (Division A) implemented the policy and were praised (and rewarded) by the corporate office. One of Division A's suppliers was another division of the company (Division B). As a result of the change in policy, Division B cut off shipments of a critical component to Division A because it paid its invoices too slowly. Because of this, Division A's shipments fell because it couldn't get the component elsewhere; costs increased (due to production stoppages); and profits dropped because of its inability to ship and invoice its customers. Division B's profits also fell because it stopped shipping to Division A.

And another . . .

In another example, a friend of mine owns a company that supplies parts to the Detroit automakers. During a visit to one of the automaker's factories, he noticed a problem in the production line with the assembly of a particular model. As part of the process, the car was flipped to enable installation of a particular subassembly. Problems occurred because the subassembly could not be completed until the car was turned back upright, and it frequently fell apart before it could be secured.

On his own accord, my friend developed an inexpensive grommet that could be placed on the subassembly to properly secure the parts as the car was flipped upright. After the final assembly was bolted together, the grommet could be easily cut away, thereby completely eliminating the problem.

the customer adopted the idea and changed the process to utilize the grommet. Even though the grommet was a very low cost part, the automaker's procurement department - in an effort to further reduce the cost - decided to purchase the grommet from a competitor instead of from the company owned by the person who developed the part. In a situation where a supplier - without direction from the customer - took the initiative to solve a problem that caused delays, extra costs, and headaches for the customer, the customer displayed a lack of respect for the supplier by awarding the business to another company. Needless to say, my friend was not motivated to solve future problems for the customer.

Stop the Madness

The above examples are unfortunately fairly typical of western business. If we are to come out of the recession strong and ready to compete, we have got to learn that the relationship with a supplier is based on more than price and payment terms. A company cannot win if its suppliers lose. Besides the obvious, who wants to do business with a loser anyway?