September 1, 2009 - DC Velocity · • Yard Management System (YMS) at Kraft – Driving Factors...
Transcript of September 1, 2009 - DC Velocity · • Yard Management System (YMS) at Kraft – Driving Factors...
September 1, 2009
Transportation Overview
Leveraging Scale & Creating
Sustainable Advantage
Michael Cole
Director Transportation Kraft Foods
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Today’s Discussion
• Company/Network Overview
• Project MOST (OTM)– Background– Transformation– Engineered Cooperative Routing– Looking Forward– Summary
• Yard Management System (YMS) at Kraft– Driving Factors– Key Considerations– Current Install Base– Our Optimal Solution– New Uses- “Fast-Track” Driver Tracking– Benefits
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Our Higher Purpose
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Our Positioning
Here’s how we’ll make today delicious:
At Kraft Foods delicious is our difference!
– We begin with our consumers.
– We make delicious foods you can feel good about.
– We believe we can make a delicious difference, everywhere.
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Fast Facts
2008
$41.9 billion in revenue
Sales in approximately 150 countries
Operations in more than 70 countries
Approximately 98,000 employees
Nearly $100 million in charitable contributions
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9 Brands with more than $1 billion in revenue
50+ Brands with more than $100 million in revenue
40+ Brands over 100 years old
An Amazing Brand Portfolio
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Kraft network locations and high level costs
Plant Store51,000
Cust DC9,000
Frozen6
Branch332
MC8
RTD5
SA Buffer18
Buffer38
OSS15
Transportation Planning and Execution - $1.2B
Upstream Logistics Execution - $0.7B
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Fullerton
San Leandro
Tulare
Fresno - Planters
Modesto
Jonesboro
Houston
Garland
Ft. Smith
Jacksonville
Champaign
Naperville
Lehigh Valley
Walton
Campbell
Avon
Rochelle
Suffolk
Coshocton
Kirksville
ColumbiaSpringfield
Mason City Davenport
New Ulm
Albany Beaver
Dam
Wausau
Madison
Woodstock
Battle
Creek
KendallvilleLowville
Dover
Newberry
- Hot Dogs, Cold Cuts,
Deli Meats &
LunchablesSandwich & recipe
cheese, Handi-Snacks
- Hot Dogs & Cold Cuts
Spray cheese
- cheese
- Cream cheese
- Pickles
Cereal
Marshmallows &
caramels
Dairy powder & cheese
Cream cheese
Cottage cheese
& sour cream
Sandwich cheese,
A1, Grey Poupon
- Bacon
Planters
- Cereal & Biscuit
Pourables &
cheese
Turkey, Cold Cuts &
Turkey Bacon
- CoffeeCereal
Dry & oil
roasted
peanuts &
Tree NutsCoffee, rice
RTD, PSD's,
Dressings,
Sauces & Mayo
- Cream cheese,
DinnersHot dogs
Ham & bacon
Lunchables
Dairy powders
Cereal -
Coffee (Ground, GFIC & Soft Pods)
RTE Shelf-Stable Pudding
Jell-O Lunchables Pudding,
Jell-O Refrigerated Snacks
and RTE Jell-O
Ontario
Aurora
Ft. Worth
Bethlehem
Norcross
Stockton
Columbus
Fullerton
San Leandro
Tulare
Fresno - Planters
Modesto
Jonesboro
Houston
Garland
Ft. Smith
Jacksonville
Champaign
Naperville
Lehigh Valley
Walton
Campbell
Avon
Rochelle
Suffolk
Coshocton
Kirksville
ColumbiaSpringfield
Mason City Davenport
New Ulm
Albany Beaver
Dam
Wausau
Madison
Woodstock
Battle
Creek
KendallvilleLowville
Dover
NewberryNewberry
- Hot Dogs, Cold Cuts,
Deli Meats &
LunchablesSandwich & recipe
cheese, Handi-Snacks
- Hot Dogs & Cold Cuts
Spray cheese
- cheese
- Cream cheese
- Pickles
Cereal
Marshmallows &
caramels
Dairy powder & cheese
Cream cheese
Cottage cheese
& sour cream
Sandwich cheese,
A1, Grey Poupon
- Bacon
Planters
- Cereal & Biscuit
Pourables &
cheese
Turkey, Cold Cuts &
Turkey Bacon
- CoffeeCereal
Dry & oil
roasted
peanuts &
Tree NutsCoffee, rice
RTD, PSD's,
Dressings,
Sauces & Mayo
- Cream cheese,
DinnersHot dogs
Ham & bacon
Lunchables
Dairy powders
Cereal -
Coffee (Ground, GFIC & Soft Pods)
RTE Shelf-Stable Pudding
Jell-O Lunchables Pudding,
Jell-O Refrigerated Snacks
and RTE Jell-O
Ontario
Aurora
Ft. Worth
Bethlehem
Norcross
Stockton
Columbus
Kraft Manufacturing and Distribution Locations
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US Distribution Networks
Dry
Plants
Ref/Frozen
Plants
RTD
Plants
CW, Boca
SBD
Pizza
Plants
Biscuit
Plants
3 PL Retail
Frozen DC’s
Frozen
Branches
Dry
Branches
DistributorChurney
Plants
Custo
mer W
arehouse
Custo
mer S
tore
Dry MC
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Ref/Frozen MC
5
FS
Dry
Plants
Ref/Frozen
Plants
RTD
Plants
CW, Boca
SBD
Pizza
Plants
Biscuit
Plants
3 PL Retail
Frozen DC’s
Frozen
Branches
Dry
Branches
DistributorChurney
Plants
Custo
mer W
arehouse
Custo
mer S
tore
Dry MC
5
Ref/Frozen MC
5
FS
L o c a t io n s C A W L o a d s # o f L a n e s
C u s t o m e r
D C 's
D P S 3 6 1 , 7 2 5 , 5 1 8 ,8 5 4 4 2 ,1 2 8 1 ,2 4 4 4 5 2
M ix in g C e n te r s 7 8 , 0 0 8 , 2 6 2 ,4 6 9 2 5 5 ,7 7 7 5 ,2 0 5 3 ,4 2 6
R T D 5 3 , 1 3 2 , 7 9 2 ,0 4 2 7 5 ,6 8 8 1 ,9 2 0 9 9 2 D r y B r a n c h e s * 9 9 2 , 3 1 2 , 1 8 6 ,4 0 9 5 2 ,5 7 3 7 6 5 n /a
F r o z e n B r a n c h e s * 2 4 5 7 5 4 , 8 0 3 ,6 1 5 2 4 ,2 0 7 6 3 2 n /a
L a n e s = O r ig in t o D e s t in a t io n ( c o m b in e s T e m p R e q u ire m e n ts a n d M o d e s )
* D r y a n d F ro z e n D a ta is S h ip m e n ts I n t o t h e B ra n c h e s , o t h e rs l in e s r e p re s e n t s h ip m e n t s to c u s t o m e r s
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US Inbound Networks
Prepaid
Suppliers(Supplier Controlled
Freight)
Aprox. 500 suppliers
Kraft
PlantsS
up
plier S
torag
eCollect
Suppliers(Kraft Controlled
Freight)
Over 400 suppliers
FullTruckload
LTL
Inter-modal
Railroad
Other
FullTruckload
LTL
Inter-modal
Railroad
Other
Kraft
Re-Packers
Kraft
External
Manufacturers
Kraft R
&P
Sto
rage
136M Loads4,230MM Lbs
3M Loads103MM Lbs
31M Loads127MM Lbs
3M Loads420MM Lbs
2M Loads3MM Lbs
94M Loads3,665MM Lbs
2M Loads163MM Lbs
5M Loads39MM Lbs
7M Loads1,075MM Lbs
0.5M Loads1.4MM Lbs
Dry
114M Loads
2,460MM Lbs
Refer
61M Loads
2,422MM Lbs
Dry
103M Loads
4,709MM Lbs
Refer
5M Loads
234MM Lbs
NOTE: Represents annual volume in terms of loads and gross weight
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At $1.2B, Transportation is the largestcomponent of supply chain spend…
Scale
• 920,000 Annual shipments (64% temp controlled)
• 400+ Inventory locations/ 3,800 customer ship to locations (Excludes DSD)
• 5 Protection classes (dry, refer, protected, conditioned, frozen)
• 25,800 Lanes (origin, destcity/ST, prot, mode)
• 6 Modes (truckload, intermodal, LTL, air, rail, backhaul)
• 285 Carriers used however the top 30 carriers handle 73% of the volume
• Top supplier (Stevens Transport) accounts for 12% of the spend. Kraft is their largest customer and accounts for ~15% of their revenue
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Transportation relationships with carriers and customers optimize cost and speed to market for Kraft…
Value AddedOptimize joint networks with customers to provide savings and growth
Leverage status as “shipper of choice” to optimize service and efficiencySpeed to market by managing relationships, business practice standardization
What We Do
Centralized Transportation Management from Madison, WI
Develop routing guides, select carriers, and monitor compliance
Develop partnerships to create level of “ownership” within the providers
CarrierStrategy
Governance/oversightrelationship mgmtsupplier selection
Industry Leverage & Customer Collaboration
Joint network optimization engineered freight
EPA Smartway size & weight
Network Execution & Continuous Improve
Trans technology cooperative routing
inbound freightfunctional alignment
OrganizationalDevelopment
Toolscommunication
training
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We often forget how large we are.
• Kraft’s total warehouse square footage of 19.5MM is equal to:
– 447 acres
– Half of Central Park in NYC
– 340 football fields
• Mileage driven of 550MM miles is equal to:
– 15 trips to Mars
– 69,500 trips around the world
• 809k loads shipped would equal:
– Trucks parked in a line would stretch 11,500 miles
– Fill four lanes of highway from NYC to San Francisco
• Kraft’s shipments consumed 98MM gallons of diesel fuel
– Could heat 200,000 homes
– Half day supply for entire US
Transportation is largely outsourced, and we continue to seek opportunities to reduce number of suppliers
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Outsourced 92% of our transportation spend…private fleet represents ~8% of our spend (13% of the loads)
$23MM
$21MM
$2MM
$106MM
$106MM
$0
$50
$100
$150
$200
$250
$300
$350
$400
$450
$500
$550
$600
$650
$700
$750$61MM
Customer Pick Up
$620MM
$748MM
Total
Intermodal
TL
LTL
DedicatedFleet
$57MM
Private Fleet*
$49MM
$49MM
$58MM $61MM
$453MM
$580MM
Common Carrier
Source: Kraft Data, A.T. Kearney AnalysisPrivate fleet excludes data for Pizza DSD and Biscuit DSD fleets
77%
7%
8%
8%
xx% = Percentage of total line haul spend
Line Haul Spend in $MM
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Outsourced 92% of our transportation spend…private fleet represents ~8% of our spend (13% of the loads)
$23MM
$21MM
$2MM
$106MM
$106MM
$0
$50
$100
$150
$200
$250
$300
$350
$400
$450
$500
$550
$600
$650
$700
$750$61MM
Customer Pick Up
$620MM
$748MM
Total
Intermodal
TL
LTL
DedicatedFleet
$57MM
Private Fleet*
$49MM
$49MM
$58MM $61MM
$453MM
$580MM
Common Carrier
Source: Kraft Data, A.T. Kearney AnalysisPrivate fleet excludes data for Pizza DSD and Biscuit DSD fleets
77%
7%
8%
8%
xx% = Percentage of total line haul spend
Line Haul Spend in $MM
1
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Project MOST
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Project MOST
Management of Organized Sustainable Transportation
• Reduce Cost
• Improve Service
• Contribute to Kraft’s Sustainability Efforts
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Transformation of the Transportation Focus
Leveraging Scale & Creating a Sustainable Advantage
Largely Transactional -------------------------------> Strategically Influential
• Managing Transportation cost is a larger concern for Kraft and our customers than ever before
• Our new capabilities within MOST offer internal productivity improvements and also opportunities to build customer relationships, delivering value in new ways
• Joint network visibility and analysis will assist in optimizing each other’s fleet assets
Enabler for Profitable Growth
Increased Supply Chain
Efficiency
Strategic Collaborative
OpportunityAssessment & Implementation
One Way – Non Collaborative Freight
Network
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Why Customers Deploy OTMBest Practices & Continuous Improvement
• Reduce costs and deliver detailed cost accounting
• Increase operations efficiency through automation
• Integrate logistics throughout the enterprise
• Logistics collaboration across all trading partners
• Improve visibility of inventory globally
• Single source of information & process control
• Increase environmental sustainability
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Project MOST: Management of Organized Sustainable Transportation
Background
• Kraft replaced the legacy transportation tool in 2006
– Partnership with Oracle to create new capabilities
– Find combinations of shipments that keep a truck loaded and moving
– Automate the execution of the shipments with new software
How It Works
• Network opportunities identified through analysis of network density and frequency
• Software segregates the shipments for priority planning – “Cooperative Routes”
• Shipments are sent to carriers via EDI for vendor execution
Benefits
• Enables the creation of an engineered network by positioning carriers in the optimal location for daily execution.
• Reduced carbon footprint: reduced empty miles
• Increased predictability for carriers enabling quality of life improvements that heavily influence driver availability
• OTM provides an integrated, single-platform solution for all areas of Transportation.
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Engineered Transportation Network Example
Fort Worth, TX
Garland, TX
ColumbiaCity, IN
Groveport, OH
Loop Detail:
Leg 1: Pickup: Columbia City, IN on Monday
Deliver: Fort Worth, TX on Wednesday
Leg 2: Pickup: Garland, TX on Wednesday
Deliver: Groveport, OH on Thursday
Oracle Transportation Management (OTM) includes a “Cooperative Route” (CR) tool which identifies repetitive loops in the network by Day of Week. Each leg of a loop found in the CR tool is specific to a day of the week.
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Cooperative Routing with ExecutionOverview
The Execution of Cooperative Routes (XCR) system will allow Kraft to execute routes in Oracle Transportation Management (OTM)
• The dynamic nature of XCR allows the system to select alternative options if the desired option is not available.
Location A
Location B
Dynamic Matching
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Validated Areas of TMS Savings
BENEFIT AREA
PERCENTAGE OF SAVINGS ON
CONTROLLABLE FREIGHT COSTS
• Mode Shift Optimization
• Streamlining Operations
• Central Load Control/Core Carrier Program
• Dedicated Fleet Continuous Moves
• Order Consolidations
• Optimal Carrier Selection
• Freight Settlement
• Replacing Older, Outdated IT Systems
• Reduced IT Integrations & Maintenance
• Improved Customer Service
� 7-30%
� 2-5%
� 5-10%
� 4-8%
� 1-2%
� 3-8%
� 2-6%
� Varies per company
� Varies per company
� Varies per company
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Looking Forward…
Project MOST lays the foundation for future opportunities:
• Leverage Scale
– Inbound Raw & Pack onto OTM. Creating additional benefits, including improved loop opportunities by adding more lanes and reducing more empty miles
– Global Platform Capability. Can use same across the world, leverage superior tool, while adhering to local needs.
– OTM “Manual” solution. Provide Transportation Optimization and visibility to areas of Kraft that are not highly integrated.
• End-to-End Management
– Procurement Optimization. Manage all pieces of the Transportation cycle in an “end to end” tool.
– Private Fleet Optimization. Significant benefit opportunity, as loads are currently “manually optimized”. Breakthrough thinking of how to integrate private fleet and common carrier priorities.
• Transformation
– Kraft/Customer Network Optimization. Partner with key customers to optimize our networks together
– Forecasting. Being able to project costs to business units, capacity requirements to carriers, risk points in network and further enhance discussions with business partners via a forward looking mind-set.
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Summary…
• MOST will over deliver on the original savings projections
• Industry leading capabilities better position Kraft to effectively manage our transportation spend in either a seller or a buyer market
• MOST helps us deliver a more sustainable transportation solution by reducing empty miles and improving the efficiencies of our carriers
• Creates new areas of collaboration with our customers
• Provides us with the simulation capabilities to properly respond to changes in the market place and within our company
• Kraft has driven change in the Transportation Industry to become the “shipper of choice” . MOST continues that industry leading change.
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Yard Management
at Kraft
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The Supply Chain “Last Mile” – The Yard
• Mixing center and plant yards are an integral part of the transportation network - delays occurred in the yard impact the overall efficiency
• Manual processes lead to lack of visibility and actionable information
Warehouse/
Plant
Yard
Distribution Center
/Plant
Trailers
Yard Truck
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Our Driving Factors to Implementa YMS
� Need for better yard tracking
� Lack of visibility for Load Control Center
� Time consuming yard checks
� Unproductive administrative time
� Believed cost savings in better management
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Key Considerations in Implementing a YMS
� Yard size and distance
� Current detention spend
� System connectivity capabilities
� Guard shack configuration
� 3PL locations
� Security & spotting contracts
� Yard definition
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Current Kraft PINC Install Base
Stockton MC
Go-Live: 2006
Ontario MC
Go-Live: 2009
Ft. Worth MC
Go-Live: 2008
Aurora MC
Go-Live: 2008
Morris RDC
Go-Live: 2008
Bethlehem MC
Go-Live: 2008
Columbus MC
Go-Live: 2007
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Our YMS Solution
Yard Hound™
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YMS Solution Overview
• Yard Hound is a suite of hardware and software system modules providing real-time information on all yard activities
– Asset status, location, and reefer temperature and fuel level
– Yard truck directives, work history, utilization statistics
– Alerts, reports, performance analysis, and yard checks
• No infrastructure needed
– Passive-RFID based tags attached to assets of interest
– GPS-enabled tracking units installed on yard trucks
– Asset locationing and yard management software running on PINC-hosted servers in the backend to receive, analyze and present information to the users over web portals
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Real-Time Visibility Enabled Yard Management
Automated, real-time
asset location, status and inventory
tracking using RFID and wireless
technologies
Web-based SW application and
GUI for communicating
real-time information
among corporate and 3rd party users
Performance analytics and
reports enabling business
process and operational efficiency
improvement
Increased Asset
Productivity
Optimized Asset
Management
Improved Asset
Visibility
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Gate Process for 3rd Party Carrier Assets
1. Scan Tag
2. Enter asset information via PINC application interface
• Use a PC or handheld reader
• Fields are customizable
3. Affix tag on trailer with magnetic mounting
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Real-Time Asset Inventory Visibility Shared Among All Users
• Automatic electronic records for all in/outbound trailers with complete asset history replacing manual logs
• Expedite in/out gate processes to reduce truck queue and idling time at the gate with increased data accuracy
• Real-time updates of database through web-based application accessible 24/7 on site or remotely, allowing all users to gain and share the same visibility (single source of the truth)
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Real-Time Asset Location Information Enables Optimized Yard Moves
• Passive RFID tags on trailers and tractors as asset IDs
• Leveraging existing yard processes – GPS-enabled RFID readers installed on the yard trucks continuously pinging the trailers while performing normal duties around the yard
• Intelligent algorithms in the server calculates trailer location and presents the information on a virtual map of the facility via a web-based SW application
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Real-Time Yard Truck Tracking
Instant status on Yard Trucks: - Current Speed- Direction - Position- Trailer ID
Up-to-the second facility map with yard truck path history
KRFT-8453
KRFT-8453
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Productivity Analytics:Yard Truck Utilization Statistics
Move TimeDrive TimeIdle TimeOff Time
Yard truck path history
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Real-Time Yard Resource Management
• Traffic managers communicate with yard truck drivers through touch-screen monitors in cabs
• Driver receives consolidated map-based move assignments from all traffic managers
• “Distances to assets” information updated continuously in real-time for individual drivers
• Leverage driver input to provide– End-of-move confirmation (verified
automatically by the RTLS)
– Exceptions
– Trailer load status
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Real-Time Asset Visibility for Carriers and CPUs: Yard Hound Carrier View
• Made available to Kraft’s carrier partners – 24 carriers signed up to-date and counting
• Online portals for carriers to view their on-site fleet status/inventory, and historical records
• Carriers can set and receive notification/alerts, and make dock appointments
• Benefits
– Streamlined communication
– Improved vendor service
– Eliminated yard checks for carriers at our facilities
– Expedited carrier fleet check-in/ check-out with permanently tagged assets
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New Ideas to Leverage the YMS -Fast-Track Driver Tracking
Driver’s information capturedvia a Paper Log from
Driver’s License:
• Driver Name• Class of License
• License Expiration Date• License State
Driver’s information capturedvia RFID tag on Driver Badge
with pre-loaded License Image:
• Driver Name• Class of License
• License Expiration Date• License State
• Driver Badge #
Today Tomorrow
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Collective Database of Drivers and Fleet Assets
• Driver’s Information associated to the RFID tag in PINC database similar to other transportation assets
• Can include information of carrier and CPU fleets to enable fast-tracking of trading partner assets– Reduce administrative
time
– Enhance collaboration and customer/vendor relationship
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Scanned badge will ping database and provide Driver Information and License Image
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Red or Green Light to Confirm Attributes Meet or Miss Requirements
MATCH - Proceed
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YMS Benefits to Date – Productivity Gains via Process Change Enabled by Visibility
• Decreased Administrative Time– Eliminated daily manual yard checks– Increasing carrier utilization of web portals and permanent fleet tagging – Researching detention– Implementing fast-track
• Asset Reduction– Reduced yard trucks through improved efficiency & resource sharing within campus– Eliminated need for overflow lot
• Spotting Opportunities– Able to monitor average moves/hour– Detailed tracking of spotter drive, move, idle and down time– Optimized moves – shorter move distance/higher number of moves per hour– Sustainable “green” yard trucks – reduced idling and search/drive miles
• Real Time Visibility and Collaboration– Sites– Carriers– Load Control Center– Customers
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Q & A
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THANK YOU!!!!