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    Supply Chain Management

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    Profit 4%

    Logistics Cost 21%

    Marketing Cost 27%

    Manufacturing Cost 48%

    Profit

    Logistics

    Cost

    Marketing

    Cost

    Manufacturing

    Cost

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    All stages involved, directly or indirectly, infulfilling a customer request

    Includes manufacturers, suppliers, transporters,

    warehouses, retailers, and customers Within each company, the supply chain includes

    all functions involved in fulfilling a customerrequest (product development, marketing,

    operations, distribution, finance, customer service) Examples: Fig. 1.1 Detergent supply chain (Wal-

    Mart), Dell

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    Customer wants

    detergent and goes

    to Jewel

    Jewel

    Supermarket

    Jewel or third

    party DC

    P&G or other

    manufacturer

    Plastic

    Producer

    Chemical

    manufacturer

    (e.g. Oil Company)

    Tenneco

    Packaging

    Paper

    Manufacturer

    Timber

    Industry

    Chemical

    manufacturer

    (e.g. Oil Company)

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    Maximize overall value created

    Supply chain value: difference between whatthe final product is worth to the customer and

    the effort the supply chain expends in fillingthe customers request

    Value is correlated to supply chain profitability(difference between revenue generated fromthe customer and the overall cost across thesupply chain)

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    Supply chain incurs costs (information, storage,transportation, components, assembly, etc.)

    The supply chain profit

    Supply chain profitability is total profit to beshared across all stages of the supply chain

    Supply chain success should be measured bytotal supply chain profitability, not profits at an

    individual stage

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    Sources of supply chain revenue: the customer

    Sources of supply chain cost: flows ofinformation, products, or funds between stages

    of the supply chain Supply chain management is the management

    of flows between and among supply chainstages to maximize total supply chain

    profitability

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    SUPPLY CHAIN MANAGEMENT SYSTEMS

    Network of organizations and business processesfor procuring raw materials, transforming into

    products, and distributing them to customers

    Materials, information, and payments flow

    through the supply chain in both directions.

    The Supply Chain

    Supply chain:

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    Coordination of business processes to speed

    information, product, and fund flows up and down

    a supply chain to reduce time, redundant effort,

    and inventory costs

    Supply chain management:

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    A Supply Chain

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    Plan: Balancing demand and supply to meet sourcing,

    production, and delivery requirements

    Source: Procurement of goods and services needed to createa product or service

    SCOR (Chain Operations Reference Model)

    identifies five major supply chain processes:

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    Make: Processes that transform a product into a

    finished state

    Deliver: Processes to manage order transportation

    and distribution

    Return: Processes associated with product returns

    and post delivery customer support

    Supply Chain Processes (Continued)

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    Key Supply Chain Management Processes

    SUPPLY CHAIN MANAGEMENT SYSTEMS

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    Figure 1.1 A Generic Supply Chain

    End product manufacturer

    Wholesalers,distributors

    Intermediate

    component mfgs.

    Raw material

    suppliers

    Retailers

    End

    customers

    Product & service flow

    Information and planning

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    PurchasingReceiving Storage Operations Storage

    Production Distribution

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    Supplier

    Supplier

    Supplier

    Storage

    }Mfg. Storage Dist. Retailer Customer

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    Supplier

    Supplier}Storage Service Customer

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    Here are two definitions:

    The design and management of seamless, value-added processacross organizational boundaries to meet the real needs of the endcustomer

    -- Institute for Supply Management

    Managing supply and demand, sourcing raw materials and parts,manufacturing and assembly, warehousing and inventorytracking, order entry and order management, distribution acrossall channels, and delivery to the customer

    -- The Supply Chain Council

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    Supply chain management is concernedwith the efficient integration of suppliers,

    factories, warehouses and stores so thatmerchandise is produced and distributed:In the right quantities

    To the right locations

    At the right time In order to

    Minimize total system cost

    Satisfy customer service requirements

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    * Firms have discovered value-enhancing andlong term benefits

    * Who benefits most? Firms with:- Large inventories- Large number of suppliers- Complex products

    - Customers with large purchasing budgets

    * Benefits- Lower purchasing/inventory costs, higher

    quality/customer service

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    Firms practicing Supply ChainManagement:

    1. Start with key suppliers2. Move on to other suppliers, customers, and

    shippers

    3. Integrate second tier suppliers and

    customers (second tier refers to thecustomers customers and the supplierssuppliers)

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    * Cost savings and better coordination of resourcesare reasons to employ Supply Chain Management

    -- Bullwhip Effect- the magnification of safety stocksand costs based on separate forecasts and uncoordinatedplanning and sharing of information along the supply

    chain (Ex. 1.1)

    * Reducing the bullwhip effect occurs through:

    -- Process integration- Interdependent activities can leadto improved quality, reduced cycle time, better

    production methods, better forecasts, less safety stock,etc.

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    Purchasing- Supplier alliances, suppliermanagement, strategic sourcing

    Operations- Demand management, MRP, ERP, JIT,TQM

    Distribution- Transportation management, customerrelationship management, networkdesign, service response logistics

    Integration- Coordination/Integration activities,global integration problems,performance measurement

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    Purchasing:

    Long term relationships

    Supplier management- improvedperformance through-

    -- Supplier evaluation (determiningsupplier capabilities and performance)

    -- Supplier certification (third party orinternal certification to assure product

    quality and service compliance)Strategic partnerships- successful andtrusting, long-term relationships with top-performingsuppliers

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    Operations:

    -- Demand management-match demand toavailable capacity

    -- Linking buyers & suppliers viaMRPandERPsystems

    -- UseJITto improve thepull of materials toreduce inventory levels

    -- EmployTQMto improve quality complianceamong buyers and suppliers

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    Distribution:-- Transportation management-tradeoff

    decisions between cost & timing ofdelivery/customer service via trucks, rail, water

    & air-- Customer relationship management-strategies to ensure deliveries, resolve

    complaints, improve communications, &determine service requirements

    -- Network design-creatingdistributionnetworksbased on tradeoff decisions between

    cost & sophistication of distribution system

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    Integration:

    -- Supply Chain Integration-when supply chainparticipants work for common goals. Requiresintra

    firmfunctional integration. Based on efforts to changeattitudes & adversarial relationships

    -- Global Supply Chains- advantages that accrue fromsourcing from larger global market e.g., lower cost &

    higher quality suppliers. May involveoperatingexposure,which is risk found in foreign settings

    -- Supply Chain Performance Measurement-Crucial forfirms to know if procedures are working

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    All of the advanced strategies, techniques,and approaches for Supply Chain

    Management focus on:

    Global Optimization

    Managing Uncertainty

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    Decision Support Systems

    Inventory Control Network Design Design for Logistics Cross Docking

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    Procurement

    Planning

    Manufacturing

    Planning

    Distribution

    PlanningDemand

    Planning

    Sequential Optimization

    Supply Contracts/Collaboration/Information Systems and DSS

    Procurement

    Planning

    Manufacturing

    Planning

    Distribution

    PlanningDemand

    Planning

    Global Optimization

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    The supply chain is complexDifferent facilities have conflictingobjectives

    The supply chain is a dynamic system

    The power structure changesThe system varies over time

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    What is variation?

    What is randomness? What tools and approaches help usto deal with these issues?

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    Forecasting is always wrong

    The longer the forecast horizon the worsethe forecast

    End item forecasts are even more wrong

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    * Matching supply and demand is difficult.

    * Forecasting doesnt solve the problem.

    * Inventory and back-order levels typically fluctuate widely acrossthe supply chain.

    * Demand is not the only source of uncertainty:Lead times

    Yields

    Transportation times

    Natural Disasters

    Component Availability

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    Volumes

    Time

    Actual

    Consumer

    DemandRetailer Warehouse

    to ShopRetailer Orders

    Production Plan

    Manufacturer Forecastof Sales

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    Volumes

    Time

    Consumer

    Demand

    Production Plan

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    Volumes

    Time

    Consumer

    Demand

    Production Plan

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    Pull Systems

    Risk Pooling

    Centralization

    Postponement

    Strategic Alliances

    Collaborative Forecasting

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    Global competition

    Shorter product life cycle

    New, low-cost distribution channels

    More powerful well-informedcustomers

    Internet and E-Business strategies

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    Supply chain strategy or design

    Supply chain planning

    Supply chain operation

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    Decisions about the structure of the supply chainand what processes each stage will perform

    Strategic supply chain decisions Locations and capacities of facilities

    Products to be made or stored at various locations

    Modes of transportation

    Information systems

    Supply chain design must support strategic

    objectives Supply chain design decisions are long-term and

    expensive to reverse must take into accountmarket uncertainty

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    Definition of a set of policies that govern short-term operations

    Fixed by the supply configuration from

    previous phase Starts with a forecast of demand in the coming

    year

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    Planning decisions:

    Which markets will be supplied from whichlocations

    Planned buildup of inventories Subcontracting, backup locations

    Inventory policies

    Timing and size of market promotions

    Must consider in planning decisions demanduncertainty, exchange rates, competition overthe time horizon

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    Customer

    Information

    Product

    Funds

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    Cycle view: processes in a supply chain aredivided into a series of cycles, each performedat the interfaces between two successive supply

    chain stages Push/pull view: processes in a supply chain

    are divided into two categories depending onwhether they are executed in response to a

    customer order (pull) or in anticipation of acustomer order (push)

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    Customer Order Cycle

    Replenishment Cycle

    Manufacturing Cycle

    Procurement Cycle

    Customer

    Retailer

    Distributor

    Manufacturer

    Supplier

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    Each cycle occurs at the interface between twosuccessive stages

    Customer order cycle (customer-retailer)

    Replenishment cycle (retailer-distributor)

    Manufacturing cycle (distributor-manufacturer)

    Procurement cycle (manufacturer-supplier)

    Cycle view clearly defines processes involved and

    the owners of each process. Specifies the roles andresponsibilities of each member and the desiredoutcome of each process.

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    Procurement,Manufacturing and

    Replenishment cycles

    Customer Order

    Cycle

    Customer

    Order Arrives

    PUSH PROCESSES PULL PROCESSES

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    Supply chain processes fall into one of twocategories depending on the timing of theirexecution relative to customer demand

    Pull: execution is initiated in response to acustomer order (reactive)

    Push: execution is initiated in anticipation ofcustomer orders (speculative)

    Push/pull boundary separates push processesfrom pull processes

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    Supply chain processes discussed in the twoviews can be classified into

    Customer Relationship Management (CRM)

    Internal Supply Chain Management (ISCM) Supplier Relationship Management (SRM)

    Integration among the above three macroprocesses is critical for effective and successful

    supply chain management

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    Gateway

    Zara

    McMaster Carr / W.W. Grainger

    Toyota

    Amazon / Borders / Barnes and Noble

    Webvan / Peapod / Jewel

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    Managing supply chain flows and assets, tomaximizesupply chain surplus

    What is supply chain surplus?

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    Competitive strategy: defines the set of customer needsa firm seeks to satisfy through its products and services

    Product development strategy: specifies the portfolioof new products that the company will try to develop

    Marketing and sales strategy: specifies how the marketwill be segmented and product positioned, priced, andpromoted

    Supply chain strategy: determines the nature of material procurement, transportation

    of materials, manufacture of product or creation of service,distribution of product

    Consistency and support between supply chain strategy,competitive strategy, and other functional strategies is

    important

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    New

    Product

    Development

    Marketing

    and

    Sales

    Operations Distribution Service

    Finance, Accounting, Information Technology, Human Resources

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    Introduction

    How is strategic fit achieved?

    Other issues affecting strategic fit

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    Strategic fit: Consistency between customer priorities of

    competitive strategy and supply chain capabilitiesspecified by the supply chain strategy

    Competitive and supply chain strategies have thesame goals

    A company may fail because of a lack of

    strategic fit or because its processes andresources do not provide the capabilities toexecute the desired strategy

    Example of strategic fit -- Dell

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    Step 1: Understanding the customer andsupply chain uncertainty

    Step 2: Understanding the supply chain

    Step 3: Achieving strategic fit

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    Identify the needs of the customer segmentbeing served

    Quantity of product needed in each lot

    Response time customers will tolerate Variety of products needed

    Service level required

    Price of the product Desired rate of innovation in the product

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    Overall attribute of customer demand

    Demand uncertainty: uncertainty of customerdemand for a product

    Implied demand uncertainty: resultinguncertainty for the supply chain given theportion of the demand the supply chain musthandle and attributes the customer desires

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    Implied demand uncertainty also related tocustomer needs and product attributes

    First step to strategic fit is to understand

    customers by mapping their demand on theimplied uncertainty spectrum

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    Understanding the Customer Lot size

    Response time

    Service level Product variety

    Price

    Innovation

    Implied

    Demand

    Uncertainty

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    Customer Need Causes implied demanduncertainty to increase because

    Range of quantity increases Wider range of quantity implies

    greater variance in demand

    Lead time decreases Less time to react to orders

    Variety of products required increases Demand per product becomes more

    disaggregated

    Number of channels increases Total customer demand is now

    disaggregated over more channels

    Rate of innovation increases New products tend to have more

    uncertain demand

    Required service level increases Firm now has to handle unusual

    surges in demand

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    Predictablesupply and

    demand

    Salt at a

    supermarket

    A newcommunication

    device

    Highly uncertain

    supply and demand

    Figure 2.2: The Implied Uncertainty (Demand and Supply)

    Predictable supply and uncertain

    demand or uncertain supply and

    predictable demand or somewhat

    uncertain supply and demand

    An existing

    automobile

    model

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    Attribute Low Implied

    Uncertainty

    High Implied

    Uncertainty

    Product margin Low High

    Avg. forecast error 10% 40%-100%

    Avg. stockout rate 1%-2% 10%-40%

    Avg. forced season-

    end markdown

    0% 10%-25%

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    How does the firm best meet demand?

    Dimension describing the supply chain issupply chain responsiveness

    Supply chain responsiveness -- ability to respond to wide ranges of quantities demanded

    meet short lead times

    handle a large variety of products

    build highly innovative products

    meet a very high service level

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    There is a cost to achieving responsiveness

    Supply chain efficiency: cost of making anddelivering the product to the customer

    Increasing responsiveness results in highercosts that lower efficiency

    Second step to achieving strategic fit is to mapthe supply chain on the responsivenessspectrum

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    High Low

    Low

    High

    Responsiveness

    Cost

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    Step is to ensure that what the supply chaindoes well is consistent with target customersneeds

    Examples: Dell,

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    Integrated

    steel mill

    Dell

    Highly

    efficient

    Highly

    responsive

    Somewhat

    efficient

    Somewhat

    responsive

    Hanes

    apparel

    Most

    automotive

    production

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    Implied

    uncertainty

    spectrum

    Responsive

    supply chain

    Efficient

    supply chain

    Certain

    demand

    Uncertain

    demand

    Responsivenessspectrum

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    All functions in the value chain must supportthe competitive strategy to achieve strategic fit Fig. 2.7

    Two extremes: Efficient supply chains (Barilla)and responsive supply chains (Dell) Table 2.3

    Two key points there is no right supply chain strategy independent

    of competitive strategy there is a right supply chain strategy for a given

    competitive strategy

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    Efficient Responsive

    Primary goal Lowest cost Quick response

    Product design strategy Min product cost Modularity to allow

    postponement

    Pricing strategy Lower margins Higher margins

    Mfg strategy High utilization Capacity flexibility

    Inventory strategy Minimize inventory Buffer inventory

    Lead time strategy Reduce but not at expense

    of greater cost

    Aggressively reduce even if

    costs are significant

    Supplier selection strategy Cost and low quality Speed, flexibility, quality

    Transportation strategy Greater reliance on low cost

    modes

    Greater reliance on

    responsive (fast) modes

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    Multiple products and customer segments

    Product life cycle

    Competitive changes over time

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    Firms sell different products to differentcustomer segments (with different implieddemand uncertainty)

    The supply chain has to be able to balanceefficiency and responsiveness given itsportfolio of products and customer segments

    Two approaches:

    Different supply chains

    Tailor supply chain to best meet the needs ofeach products demand

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    The demand characteristics of a product andthe needs of a customer segment change as aproduct goes through its life cycle

    Supply chain strategy must evolve throughoutthe life cycle

    Early: uncertain demand, high margins (time isimportant), product availability is most

    important, cost is secondary Late: predictable demand, lower margins, price

    is important

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    Examples: pharmaceutical firms, Intel

    As the product goes through the life cycle, thesupply chain changes from one emphasizing

    responsiveness to one emphasizing efficiency

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    Competitive pressures can change over time

    More competitors may result in an increasedemphasis on variety at a reasonable price

    The Internet makes it easier to offer a widevariety of products

    The supply chain must change to meet thesechanging competitive conditions

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    Scope of strategic fit The functions and stages within a supply chain that

    devise an integrated strategy with a shared objective

    One extreme: each function at each stage develops itsown strategy

    Other extreme: all functions in all stages devise a strategyjointly

    Five categories: Intracompany intraoperation scope

    Intracompany intrafunctional scope Intracompany interfunctional scope

    Intercompany interfunctional scope

    Flexible interfunctional scope

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    Suppliers Manufacturer Distributor Retailer Customer

    Competitive

    Strategy

    ProductDevelopment

    Strategy

    Supply Chain

    Strategy

    Marketing

    Strategy

    Intracompany

    Intraoperation

    at Distributor

    Intracompany

    Intrafunctional

    at Distributor

    Intracompany

    Interfunctional

    at Distributor

    IntercompanyInterfunctional

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    Facilities places where inventory is stored, assembled, or fabricated

    production sites and storage sites

    Inventory

    raw materials, WIP, finished goods within a supply chain

    inventory policies

    Transportation

    moving inventory from point to point in a supply chain

    combinations of transportation modes and routes

    Information

    data and analysis regarding inventory, transportation, facilities

    throughout the supply chain potentially the biggest driver of supply chain performance

    Sourcing

    functions a firm performs and functions that are outsourced

    Pricing

    Price associated with goods and services provided by a firm to thesupply chain

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    Competitive Strategy

    Supply Chain

    Strategy

    Efficiency Responsiveness

    Facilities Inventory Transportation

    Information

    Supply chain structure

    Cross Functional Drivers

    Sourcing Pricing

    Logistical Drivers

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    Role in the supply chain the where of the supply chain

    manufacturing or storage (warehouses)

    Role in the competitive strategy economies of scale (efficiency priority)

    larger number of smaller facilities (responsivenesspriority)

    Components of facilities decisions

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    Location centralization (efficiency) vs. decentralization

    (responsiveness)

    other factors to consider (e.g., proximity to customers)

    Capacity (flexibility versus efficiency)

    Manufacturing methodology (product focusedversus process focused)

    Warehousing methodology (SKU storage, job lotstorage, cross-docking)

    Overall trade-off: Responsiveness versus

    efficiency

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    Role in the supply chain Role in the competitive strategy

    Components of inventory decisions

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    Inventory exists because of a mismatch betweensupply and demand

    Source of cost and influence on responsiveness

    Impact on

    material flow time: time elapsed between whenmaterial enters the supply chain to when it exits thesupply chain

    throughput

    rate at which sales to end consumers occur

    I = RT (Littles Law)

    I = inventory; R = throughput; T = flow time

    Example

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    If responsiveness is a strategic competitivepriority, a firm can locate larger amounts ofinventory closer to customers

    If cost is more important, inventory can bereduced to make the firm more efficient

    Trade-off

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    Cycle inventory Average amount of inventory used to satisfy demand between

    shipments

    Depends on lot size

    Safety inventory inventory held in case demand exceeds expectations

    costs of carrying too much inventory versus cost of losing sales

    Seasonal inventory

    inventory built up to counter predictable variability in demand cost of carrying additional inventory versus cost of flexible

    production

    Overall trade-off: Responsiveness versus efficiency more inventory: greater responsiveness but greater cost

    less inventor : lower cost but lower res onsiveness

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    Role in the supply chain Role in the competitive strategy

    Components of transportation decisions

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    Moves the product between stages in thesupply chain

    Impact on responsiveness and efficiency

    Faster transportation allows greaterresponsiveness but lower efficiency

    Also affects inventory and facilities

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    If responsiveness is a strategic competitivepriority, then faster transportation modes canprovide greater responsiveness to customerswho are willing to pay for it

    Can also use slower transportation modes forcustomers whose priority is price (cost)

    Can also consider both inventory and

    transportation to find the right balance

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    Mode of transportation: air, truck, rail, ship, pipeline, electronic

    transportation

    vary in cost, speed, size of shipment, flexibility

    Route and network selection

    route: path along which a product is shipped

    network: collection of locations and routes

    In-house or outsource Overall trade-off: Responsiveness versus

    efficiency

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    Role in the supply chain Role in the competitive strategy

    Components of information decisions

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    The connection between the various stages inthe supply chain allows coordinationbetween stages

    Crucial to daily operation of each stage in asupply chain e.g., production scheduling,inventory levels

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    Allows supply chain to become more efficientand more responsive at the same time (reducesthe need for a trade-off)

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    Push (MRP) versus pull (demand informationtransmitted quickly throughout the supplychain)

    Coordination and information sharing Forecasting and aggregate planning

    Enabling technologies

    EDI

    Internet

    ERP systems

    Supply Chain Management software

    Overall trade-off: Responsiveness versus

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    Role in the supply chain Role in the competitive strategy

    Components of sourcing decisions

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    Set of business processes required to purchasegoods and services in a supply chain

    Supplier selection, single vs. multiple

    suppliers, contract negotiation

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    Sourcing decisions are crucial because theyaffect the level of efficiency and responsivenessin a supply chain

    In-house vs. outsource decisions- improvingefficiency and responsiveness

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    In-house versus outsource decisions Supplier evaluation and selection

    Procurement process

    Overall trade-off: Increase the supply chainprofits

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    Role in the supply chain Role in the competitive strategy

    Components of pricing decisions

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    Pricing determines the amount to chargecustomers in a supply chain

    Pricing strategies can be used to match demand

    and supply

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    Firms can utilize optimal pricing strategies toimprove efficiency and responsiveness

    Low price and low product availability; vary

    prices by response times

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    Pricing and economies of scale Everyday low pricing versus high-low pricing

    Fixed price versus menu pricing

    Overall trade-off: Increase the firm profits

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    Increasing variety of products Decreasing product life cycles

    Increasingly demanding customers

    Fragmentation of supply chain ownership Globalization

    Difficulty executing new strategies