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TOTAL SUPPLY CHAIN MANAGEMENT. syllabus. CUSTOMER AND THEIR SERVICE 1 INTORDUCTION TO SUPPLY CHAIN MANAEMENT 2 RECENT BUSINESS STRATEGIES AND GLOBALIZATION 3 SUPPLY CHAIN BREAKERS 4 LOGISCTICS AND COMPETITIVE STRATEGY 5 TOTAL DISTRIBUTION AND COST PERFORMANCE – AUDITING 6

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Syllabus
syllabus

  • CUSTOMER AND THEIR SERVICE 1

  • INTORDUCTION TO SUPPLY CHAIN MANAEMENT 2

  • RECENT BUSINESS STRATEGIES AND GLOBALIZATION 3

  • SUPPLY CHAIN BREAKERS 4

  • LOGISCTICS AND COMPETITIVE STRATEGY 5

  • TOTAL DISTRIBUTION AND COST PERFORMANCE – AUDITING 6

  • MEASUREMENT OF SUCCESS AND BENCHMARKING 7

  • INSIGHT OF MATERIALS MANAGEMENT 8

  • PURCHASE ORGANIZATION 9

  • PROCUREMENT PROCUDERE AND POLICY 10

  • VENDOR DEVELOPMENT AND EVALUATION 11

  • TYPES OF PURCHASE 12

  • COST ELEMENTS 13

  • ECONOMIC ORDER QUANTITY (EOQ) AND JUST IN TIME (JIT) 14

  • COMPUTER SUPPORT IN MATERIAL MANAGEMENT 15

  • TRANSPORTAION AND INFRASTRUCTRUE 16

  • INVENTORY CONCEPT AND ANALYSIS 17

  • PLAN AND WAREHOUSE 18

  • MATERIALS HANDLING AND PACKAGING 19

  • DISTRIBUTION NETWORK DESIGN AND CHANNELS OF DISTRIBUTION 20

  • FACILITY LOCATION DECISION 21

  • INFORMATION SYSTEM 22

  • CASE STUDIES


Unit i

UNIT I

CUSTOMER AND THEIR SERVICE


Introduction
Introduction

  • The customer is the main factor for whom the business is run and due to his satisfaction the business is flourishing.

  • Earlier it was seller’s market and the importance of customer satisfaction is rarely understood.

  • As the situation turns to the buyer’s market, the customer importance increases.


Customer service performance
Customer service performance

Customer service is defined as

  • An activity or function to be managed such as order processing or handling of customer complaints.

  • Actual performance on parameters such as ability to ship orders within a certain period.

  • Part of an overall corporate philosophy.

  • The essence of demand management is to improve the ability of firms throughout the supply chain particularly manufacturing through the customer by considering their satisfaction.


The number of ways in which effective demand management will help the common goal of providing efficient customer service and thereby satisfying customers and solving their problems are as below:

  • Gathering and analyzing knowledge about consumers, their problems and their unmet needs.

  • Identifying partners to perform the functions needed in the demand chain.

  • Assigning the functions that need to be done to the channel member that can perform them mostly effectively and efficiently.


  • Sharing with other supply chain members knowledge about consumers and customers, available technology and logistics challenges and opportunities.

  • Delivering and executing the best logistics, transportation and distribution methods to deliver product and services to consumers in the desired manner.


The customer service dimension
The customer service dimension consumers and customers, available technology and logistics challenges and opportunities.

  • It highlights the importance of managing the marketing and logistics interface on an integrated basis, emphasizes the need to understand the multiple elements of service from the customers’ perspective.

  • From the point of view of logistics function, customer service can be viewed as having four dimensions:

    • Time

    • Dependability

    • Communication

    • Convenience


Time consumers and customers, available technology and logistics challenges and opportunities.

  • The time factor is usually order cycle time from the perspective of seller looking at customer service.

  • The buyer usually refers to the time dimension as the lead time or replenishment time .


Dependability
Dependability consumers and customers, available technology and logistics challenges and opportunities.

  • Some customers consider dependability as more important than lead time.

  • The customer firm can minimize its inventory level if lead time is fixed.

  • This means there is no need to keep safety stock to ground against stock outs resulting from fluctuating lead times.

  • Cycle time provides a dependable lead time reduces some of the uncertainty a customer faces.

  • Lead time dependability directly affects customers inventory level and stock out costs.


Communication
Communication consumers and customers, available technology and logistics challenges and opportunities.

  • The two logistics activities vital to order filling are the communication of customer order information to the order – filling area and the actual process of picking out of the inventory, the items ordered.

  • Communication must be a two – way process.

  • The seller must be able to transmit vital logistics service information to the customer.

  • Say for eg., information concerning shipment date, the carrier, the route etc.


Convenience
Convenience consumers and customers, available technology and logistics challenges and opportunities.

  • This means the logistics service level must be flexible.

  • Convenience recognizes customers different requirements.

  • a seller can group custom requirement by such factors as customer size, market area and the product line the customer is purchasing.

  • This level market segmentation enables the logistics manager to recognize customer service requirements and to attempt to fulfill those demands economically as possible.


The customer service elements
The customer service elements consumers and customers, available technology and logistics challenges and opportunities.

  • There are three customer service elements:

    • Pre – transaction elements

    • Transaction elements

    • Post – transaction elements


Pre transaction elements
Pre – transaction elements consumers and customers, available technology and logistics challenges and opportunities.

  • Written customer service policy

    • Is it communicated internally and externally

    • Is it understood

    • Is it specific and quantified where possible?

  • Accessibility

    • Are we easy to contact or do business with?

  • organization structure

    • Is there a customer service management structure in place?

    • What level of control do they have over their service process?

  • System flexibility

    • Can we adapt our service delivery systems to meet particular customer needs?


Transaction elements
Transaction elements consumers and customers, available technology and logistics challenges and opportunities.

  • Order cycle time

    • What is the elapsed time from order to delivery?

    • What is the reliability / variation?

  • Inventory availability

    • What percentage of demand for each item can be met from stock?

  • Order fill rate

    • What proportion of orders are completely filled within the stated lead time?

  • Order status information

    • How long does it take us to respond to a querry with the required information?

    • Do we inform the customer of problems or do they contact us?


Post transaction elements
Post – transaction elements consumers and customers, available technology and logistics challenges and opportunities.

  • Availability of spares

    • What are the in-stock levels of service parts?

  • Call – out time

    • How long does it take for the engineer to arrive?

    • What is the first call fix rate?

  • Product tracing / warranty

    • Can we identify the location of individual products once purchased?

    • Can we maintain/ extend the warranty to customers’ expected levels?

  • Customer complaints, claims etc.


Customer satisfaction
Customer satisfaction consumers and customers, available technology and logistics challenges and opportunities.

  • Customer satisfaction is the customer’s overall measurement of all elements of the logistics management, such as product, price, promotion and place.

  • Customer service is also a part of the customer satisfaction.


The 3 r s in customer service
The 3 R’s in customer service consumers and customers, available technology and logistics challenges and opportunities.

  • Many companies have the concept of following the 3 R’s in the customer service. They are

    • Respect your customer

    • Take Responsibility for your actions and products

    • Give your customer a full Refund when it just isn’t right


7 unhealthy attitudes of disrespect
7 unhealthy attitudes of disrespect consumers and customers, available technology and logistics challenges and opportunities.

  • Unprofessional greetings.

  • Staff who do not know the company mission statement.

  • Staff who do not know the product.

  • Staff who do not understand that the customer is the only reason they are getting a paycheck.

  • Management who don’t listen to staff on how to “fix” customer service

  • Giving the front line staff the authority to “fix” a customer problem on the spot

  • Respect customer’s time


7 steps for customer retention
7 steps for customer retention consumers and customers, available technology and logistics challenges and opportunities.

  • Offer only proven and quality services and / or products.

  • Demonstrate customer appreciation.

  • Provide responsive and pro – active customer service.

  • Give instruction on how to get the most use from products and / or service.

  • Share testimonials from customers with other customers and potential customers.

  • Educate the customer about the industry or market and about the value of the business.

  • Invite customer’s opinion and feedback on products and / or services.

    retaining more customers can result in significantly higher profits to the organizations.


Customer service and levels of product
Customer service and levels of product consumers and customers, available technology and logistics challenges and opportunities.

  • Customer service can be thought of as something a firm provides to those who purchase its products or services.

  • According to market there are three levels of products:

    • The core benefit or service which constitutes what the buyer really buying.

    • The tangible product or the physical product or service itself.

    • The product which includes benefits that are secondary to it but an integral enhancement to the tangible product the customer is purchasing. Say features like installation, warranties and after-sales-service.


Customer service consumers and customers, available technology and logistics challenges and opportunities.

  • Is a concept whose importance reaches far beyond the logistics area.

  • Customer service frequently affects every area of the firm by attempting to ensure customer satisfaction through the provision of service to the customer.

  • Examples of customer service are

    • Providing financial and credit terms.

    • Guaranteeing delivery within specified time period.

    • Installing a product.

    • Maintaining satisfactory spare parts inventory.

    • Revamping a billing procedure to accommodate a customer’s request.


Levels of customer service
Levels of customer service consumers and customers, available technology and logistics challenges and opportunities.

  • There are 3 levels of customer service,

  • Customer service as an activity:

    • This level treats customer service as a particular task that a firm must accomplish to satisfy the customers needs.

  • Customer service as performance measures:

    • This level emphasizes customer service in terms of specific performance measures such as the percentage of orders delivered on time and complete and the number of orders processed within acceptable time limits.

  • Customer service as philosophy:

    • This level elevates customer service to a firm wide commitment to providing customer satisfaction through superior customer service.


Implementing customer service standards
Implementing customer service standards consumers and customers, available technology and logistics challenges and opportunities.

The key for successfully developing and implementing customer service standards are:

  • To be wary of adopting easily achievable performance standards.

  • Emphasis on total quality or on creation of the “perfect order” are very critical to any acceptable quality level set below 100 percent.

  • The firm should develop customer service policies and standard through customer consultation.

  • The firm should develop procedures to measure, monitor and control the customer service quality called for by the firm performance measures and standards.


Customer service issues
Customer service issues consumers and customers, available technology and logistics challenges and opportunities.

The questions guide in developing a sound customer service policy and standard performance:

  • What do customers feel about present levels of service?

  • Do their perceptions match up with ours?

  • How do our services compare to those of our competitors?

  • Are we using appropriate standards and measurements to monitor our service performance?

  • Is it possible to segment our customers according to the varying degrees of service they require?

  • Can we produce the same levels of service we are presently providing in amore cost – effective manner?

  • Can improved customer service be used as a strategic weapon to provide an important competitive advantage?

  • In the minds of our customers, how important is service compared to other elements of the marketing like price, promotion and products?


Improving customer service performance
Improving customer service performance consumers and customers, available technology and logistics challenges and opportunities.

The levels of customer service a firm achieves, often can be improved through one or more of the following actions:

  • Thoroughly researching customer needs.

  • Setting service levels that make realistic trade – offs between revenues and expenses.

  • Making use of the latest technology in order of processing systems.

  • Measuring and evaluating the performance of individual logistic activities.


Improving customer service performance1
Improving customer service performance consumers and customers, available technology and logistics challenges and opportunities.

Automation improves customer service by providing the following benefits to the customer:

  • Better product availability

  • More accurate invoices

  • The ability to reduce stock levels and their associated inventory carrying costs

  • Improved access for information on order status.

  • Automated order processing systems enhance the firs’s ability to perform all the transaction and post – transaction elements of customer service.


Improving customer service performance2
Improving customer service performance consumers and customers, available technology and logistics challenges and opportunities.

Finally the development of an effective customer service program requires the establishment of customer service standards which performs the following functions:

  • Reflect the customer’s view point

  • Provide an operational and objective measure of service performance

  • Provide management with cues for corrective action and improvement of customer service.


Methods to give customer service
Methods to give customer service consumers and customers, available technology and logistics challenges and opportunities.

  • Hire people who have a service attitude.

  • Make the customer’s time with you an experience.

  • Regularly inform all your employees about what’s going on in your company.

  • Make every decision with the customer in mind.

  • Make the customers know an agenda item at every staff meeting.

  • Empower your employees to do the right thing.

  • Continually ask yourself how you can improve and add value.

  • Create an atmosphere of excellence.

  • Continually do the unexpected.

  • Never let an untrained employee have customer contact.


Unit 2

UNIT 2 consumers and customers, available technology and logistics challenges and opportunities.

INTRODUCTION TO SUPPLY CHAIN MANAGEMENT(SCM)


Introduction1
Introduction consumers and customers, available technology and logistics challenges and opportunities.

  • Supply chain management is the systematic, strategic coordination of the traditional business functions within a particular company and across the business within the supply chain, for the purpose of improving performance.

  • It consist of a company, immediate supplier, immediate customer directly linked by one or more of the upstream and downstream flows of product , services, finance and information.


Scm concept
SCM concept consumers and customers, available technology and logistics challenges and opportunities.

  • Successful companies smartly manage the 4 key business resources of Man, Material, Money and Information.

  • Proper planning and efficient management of flows of material and related information from supplier to the customer through the organization forms the major responsibility of supply chain management.

  • SCM consists of developing smarter ways to choose, buy from and sell to the business partners of the organization.

  • Every interface in the supply chain represents movement of goods, information flow, transfer of documents and purchase and sale.


Activities of scm
Activities of SCM consumers and customers, available technology and logistics challenges and opportunities.

  • This is an extended enterprise that spreads across company encompassing the logistics related activities of all the firm involved in the supply chain.

  • This extended enterprise integrates the flow of materials, services, information and finances into a coordinated flow across all the enterprises,

  • This integration across the company means that the supply chain functions like a single company satisfying the ultimate customer.

  • The suppliers in SCM got many advantages in developing ‘partnership’ with customer firms.


Objectives of scm
Objectives of SCM consumers and customers, available technology and logistics challenges and opportunities.

  • Solving supplier’s problems and beyond his level.

  • Customer service performance improvement

  • Reduction of pre and post production inventory.

  • Minimizing variance by means of activities like standardization, variety reduction, etc.

  • Minimum total cost of operations and procurement.

  • Product quantity control.

  • Achieving maximum efficiency in using labor, capital and plant throughout the company.

  • Flexible planning and control production.


Supply chain characteristics
Supply Chain Characteristics consumers and customers, available technology and logistics challenges and opportunities.

Service response

Integration of information

Technology assimilation

Workflow coordination

Synchronization

The trust

Quick response

Efficient customer response


Advantages of scm
Advantages of SCM consumers and customers, available technology and logistics challenges and opportunities.

  • Benefits to the customer:

    • The benefits the customer will get by dealing with a well-managed vendor due to an effective supply chain organization are as follows:

    • Improved customer service through fewer shortages.

    • Improved product cost.

    • Better delivery performance.

    • Quicker response to changes in demand.

    • Optimal purchase cost due to possibility of long-term purchase contracts.


Advantages of scm1
Advantages of SCM consumers and customers, available technology and logistics challenges and opportunities.

  • Benefits to the company

    • A company with a well functioning supply chain organization has the competitive edge.

    • It is capable of satisfying customer needs for flexibility, competitive price, quicker response time and shorter lead times.

    • The company gets the following benefits:

    • Reduction in tied-up capital and administrative costs due to reduction / elimination of inventory at all levels.

    • Reduction in time and money lost through production line stoppage.

    • More flexibility in planning.

    • Sustained growth of sales and company business.

    • Increased shareholder value.


Unit 3

UNIT 3 consumers and customers, available technology and logistics challenges and opportunities.

RECENT BUSINESS STRATEGY AND GLOBALIZATION


Modern concept of business
MODERN CONCEPT OF BUSINESS consumers and customers, available technology and logistics challenges and opportunities.

  • The modern concept of business is more progressive, liberal and consumer oriented.

  • There is a modern concept of consumer – centered / service – orientation to business activities.

  • It starts and ends with the consumer


Features of modern business
Features of modern business consumers and customers, available technology and logistics challenges and opportunities.

  • Large scale production and distribution of goods and service

  • Mass production and mass marketing

  • Diversification and globalization of business

  • Decentralization of production and E-commerce techniques of marketing


Features of modern business cond
Features of modern business cond… consumers and customers, available technology and logistics challenges and opportunities.

  • Cutthroat competition at national and global levels on the basis of cost, quality, attractiveness and publicity to products and services.

  • Extensive use of computers and other information technology techniques in business management.

  • Increasing participation of government in business and widening the scope of regulatory role of the government.


Features of modern business cond1
Features of modern business cond… consumers and customers, available technology and logistics challenges and opportunities.

  • Emergence of consumerism, environment protection movement and consumer protection laws.

  • Modern business is dynamic.

  • It is flexible to change due to technological and other factors relating to production activities


Recent business trend
Recent business trend consumers and customers, available technology and logistics challenges and opportunities.

  • Work anywhere for any body

  • Big organization no longer needed

  • Small business undertaking one activity in depth

  • Work form home

  • Outsourcing – is partnership with a company who’s responsibility is to resolve any problems.

  • Globalization of business


Benefits of out sourcing
Benefits of out sourcing consumers and customers, available technology and logistics challenges and opportunities.

  • Cost saving

  • Leads to lean organization

  • Responsibility to the outsider

  • Better controls on quality and schedules

  • Can be done at several places in the country

  • Provides flexibility as it can be stopped at any time

  • Reduced liability

  • Expansion can be done easily.


Globalization of business
Globalization of business consumers and customers, available technology and logistics challenges and opportunities.

  • Globalization of business means expansion of business activities to cover the entire world within its scope.

  • Globalization leads to integration of economies of different countries in a new global economic order.

  • Globalization is a process of integrating country’s economy with global economy with a view to capturing global opportunities for long term growth and development.


Features of global business
Features of global business consumers and customers, available technology and logistics challenges and opportunities.

  • Large scale production and marketing.

  • Connecting of economies of countries.

  • Importance of developed countries an MNC’s.

  • Advantageous for participating countries.

  • Tough competition among companies.

  • Important role played by science and technology.


Features of global business cond
Features of global business cond… consumers and customers, available technology and logistics challenges and opportunities.

  • World – wide restrictions on products, technology and capital.

  • Sensitive nature of global business.

  • Participation of global agencies.

  • Interdependence at global level.

  • Revolutionary changes in manufacturing and marketing concepts.


Need of globalization
Need of Globalization consumers and customers, available technology and logistics challenges and opportunities.

  • Expansion of production and exports.

  • Making domestic industries competitive.

  • Effective utilization of surplus production.

  • Securing benefits of research and develop activities.

  • Changed global situation


Benefits of globalization
Benefits of globalization consumers and customers, available technology and logistics challenges and opportunities.

Benefits to participation countries:

  • Integration of countries.

  • Faster economic growth.

  • Transfer of capital and technology.

  • New global economic order.

  • Opportunities to expand business and promote exports

  • Optimum utilization of resources

  • Higher status


Benefits of globalization1
Benefits of globalization consumers and customers, available technology and logistics challenges and opportunities.

Benefits to participating companies / enterprises:

  • High profit

  • Benefits of liberal government facilities

  • Expansion in business activities

  • Spreading business risks

  • Better utilization of resources

  • Raises competitive capacity

  • Contribution to national economy


Disadvantages of globalization
Disadvantages of globalization consumers and customers, available technology and logistics challenges and opportunities.

  • Free entry of foreign companies in domestic markets

  • Expansion in the activities of MNC’s

  • Difficulties before domestic companies

  • Adverse effects on national economy

  • Brain drain

  • Liberal trade policies may prove harmful to poor/developing countries.

  • Extensive use of capital intensive technology is harmful


India s participation in global business
India’s participation in global business consumers and customers, available technology and logistics challenges and opportunities.

  • Our participation in global business is expected to give certain benefits such as:

    • Promotion of exports.

    • Inflow of foreign capital and technology.

    • Modernization of Indian industries.

    • Generation of employment opportunities within the country.

    • Easy repayment of foreign debts.

    • Creation of favorable balance of payments position with comfortable foreign exchange balance.


Policy of the government on globalization
Policy of the government on globalization consumers and customers, available technology and logistics challenges and opportunities.

  • Continuous efforts for linking Indian economy with global economy.

  • Wider exposure given to Indian economy.

  • Supportive policy.

  • Step in the right direction.


Supply chain breakers

SUPPLY CHAIN BREAKERS consumers and customers, available technology and logistics challenges and opportunities.

UNIT 4


Introduction2
Introduction consumers and customers, available technology and logistics challenges and opportunities.

  • Let us discuss some cases of day–to–day problems taking place in different fields.

  • This helps us to understand the subject matter in good clarity.

  • It may give us some idea by which we can understand the importance and simplicity of the subject.


Unit 6

UNIT consumers and customers, available technology and logistics challenges and opportunities.6

TOTAL DISTRIBUTION AND COST PERFORMANCE - AUDITING


Cost consumers and customers, available technology and logistics challenges and opportunities.

  • Is the expenses incurred by the company on the activities of logistics.

  • These may be high or low on the basis of the efficiency of these activities.

  • The expenses involved in logistics activities are

    • Transportation cost

    • Inventory cost

    • Warehousing cost

    • Local delivery cost

    • Order processing cost


Conventional costing method
Conventional costing method consumers and customers, available technology and logistics challenges and opportunities.

  • The expenses are collected in such a way that all the factory expenses are apportioned to calculate the product cost.

  • This method of costing is difficult to find the expenses of logistic activities.

  • In this method direct expenses are easy to get but indirect expenses are difficult to get.

  • In this method the product price only can be calculated.


Activity based costing
Activity based costing consumers and customers, available technology and logistics challenges and opportunities.

  • The expenses are collected by the persons working in the related areas.

  • The logistics cost is identified in the areas as follows:

    • No. of days material is in the stores waiting for order.

    • No. of receipts in the receiving stores.

    • No. of man hours spent by persons in the material handling section.

    • No. of packing done for dispatches.

    • No. of new customers developed.

    • No. of errors in invoice.


Performance measurement
Performance measurement consumers and customers, available technology and logistics challenges and opportunities.

  • Measurements are the key to success.

  • Lowering cost, improving service, etc are the needs.

  • People behave based on the way they are measured.

  • Do grading methods influence your actions?

  • What gets measured typically improves.

  • Creates focus and attention.

  • Reduce their operating costs.

  • Drive their revenue growth

  • Enhance their shareholder value.


Methodology for measurement
Methodology for measurement consumers and customers, available technology and logistics challenges and opportunities.

  • Have a scoreboard

  • Use standardized methods

  • Fix and stick with the targets

  • Adopt a holistic approach

  • Work on the right things


Logistics performance measures
Logistics performance measures consumers and customers, available technology and logistics challenges and opportunities.

  • It is classified as either effectiveness measures or efficiency measures.

  • Logistics performance of a company can be improved in the following areas.

  • Trading problem

    • On time delivery

    • Customer complain

    • Over delivery

    • Short delivery

    • Damages in delivery


  • Returns and allowances consumers and customers, available technology and logistics challenges and opportunities.

  • Longer cycle time

  • Customer satisfaction

  • Sales outstanding in days

  • Accuracy of the forecast

  • Accuracy of invoice

  • Perfect order fulfillment

  • Inquiry response time

  • Utilization problem

    • Space utilization against capapcity

    • Equipment down time

    • Equipment utilization against capacity

    • Labor utilization against capacity


    • In company problems consumers and customers, available technology and logistics challenges and opportunities.

      • Inventory count accuracy

      • Order fill

      • Out of stocks

      • Line item fill

      • Back order

      • Inventory obsolescence

      • Incoming material quality

      • Processing accuracy

      • Case fill

      • Cash cycle time


    • Productivity consumers and customers, available technology and logistics challenges and opportunities.

      • Finished goods inventory turnover

      • Order processing / labour

      • Products units processed per warehouse

      • Number of products made against time

      • Order processing / time

      • Product units processed per transportation

    • Cost

      • Out bound freight cost

      • Inbound freight cost

      • Inventory carrying cost

      • 3rd party storage cost

      • Logistics cost against budget

      • Cost of servicing inventory


    Performance measure
    Performance measure consumers and customers, available technology and logistics challenges and opportunities.

    • Financial measures

    • Productivity measures


    Financial measures
    financial measures consumers and customers, available technology and logistics challenges and opportunities.

    • As a great deal of money in spent on logistics operations, it is necessary to monitor and control related costs.

    • Some formulas to measure logistics expense (LE)

      Logistics Assert Value (LAV)

      = sum total value of logistics assets deployed

      Return on Logistics Asserts (RLA)

      = Profit / LAV

      Logistics Asset Turnover (LAT)

      = Revenue / LAV


    Logistics Capital Charges (LCC) consumers and customers, available technology and logistics challenges and opportunities.

    = LAV * Asset Carrying Rate

    Total Logistics Cost TLC

    = LE + LCC

    Logistics Cost to Sales (LSCR)

    = TLC / Revenue

    Logistics Value Added (LVA)

    = After tax profit – Logistics capital charges


    Productivity measures
    Productivity measures consumers and customers, available technology and logistics challenges and opportunities.

    • This is a measure of how well resources are performing and managed.

    • The resources are as shown.

    Logistics Resources

    Working persons

    Inventory

    Transportation system

    information

    Logistics Operation

    Transportation

    Supply to customer

    Inventory management

    Customer response

    warehousing

    Logistics output

    Perfect orders

    Storage capacity information

    sales

    costs


    Unit 7

    UNIT 7 consumers and customers, available technology and logistics challenges and opportunities.

    MEASUREMENT OF SUCCESS AND BENCHMARKING


    Performance measures
    Performance measures consumers and customers, available technology and logistics challenges and opportunities.

    • Performance measures of successful BPR should provide

      • A basis for understanding

      • A means to focus efforts on areas for improvements in effectiveness, efficiency and adaptability.

    • Constructing a performance measurement systems in

      • Financial

      • Customer

      • Internal

      • Innovation & learning

      • Customer profitability analysis

      • Analysis of value addition


    BPR consumers and customers, available technology and logistics challenges and opportunities.

    • Is a concept of reviewing and making probable changes to the organization's infrastructure.

    • Steps to restructure the organization

      • Review the organization’s people resources: structure, competence and motivation

      • Review structure and technological capability

      • Formulate new organizational form

      • Define new roles, coach and train employees

      • Build new technological infrastructure and application


    Advantages of measurement
    Advantages of measurement consumers and customers, available technology and logistics challenges and opportunities.

    • Reduction of manpower in a process

    • Improvement in turnover of the company

    • Improvement in the profits

    • Reduction in the cycle time of specific activity

    • Solving the points of hindrances in a process

    • Reduction in point area in a process

    • Improving market share of the company

    • Improvement in the customer services

    • Increase in the satisfaction for the employees

    • Improvement in the accuracy of data and information of the employees

    • Improvement in the company share value

    • Reducing new product introduction period


    Benchmarking
    Benchmarking consumers and customers, available technology and logistics challenges and opportunities.

    • It can highlight areas for improvement by pointing out what is possible.

    • Benchmarking can be undertaken by comparing between

      • Different departments within a division

      • Different divisions within a company or organization

      • Different organizations within the same industry

      • Different organizations in different industries


    Benchmarking cond
    Benchmarking consumers and customers, available technology and logistics challenges and opportunities.cond…

    • The comparisons can be made across a range of activities and they are:

      • Budgetary or financial performance

      • Customer service delivery systems and measures

      • Productivity measures

      • Use of technology

      • Planning and project management practices

      • Human resources management

      • Financial control systems


    Merits of benchmarking
    Merits of benchmarking consumers and customers, available technology and logistics challenges and opportunities.

    • Understand existing process

    • To set Goals and Measures

    • To measure the current status

    • To set the benchmark there by increasing the output of the organization


    Unit 8

    UNIT consumers and customers, available technology and logistics challenges and opportunities. 8

    INSIGHT OF MATERIAL MANAGEMENT


    Introduction3
    Introduction consumers and customers, available technology and logistics challenges and opportunities.

    • Material is the central item and the activity of any organization

    • The main purpose of any organization is to make profit

    • This profit or loss gets generated due to material

    • Organization exists for material, works for material and due to material


    The organization of material
    The organization of material consumers and customers, available technology and logistics challenges and opportunities.

    • The materials department is generally having following subsections:

      • Office and administration activities

      • Purchase

      • Receiving the incoming material

      • Stores and warehousing

      • Transport and internal material movement

      • Dispatching the semi-finished and finished material

    • The functions of 2 – 6 are coordinated and headed by 1.


    Objectives of material management
    Objectives of material management consumers and customers, available technology and logistics challenges and opportunities.

    • To buy materials and services

      • of the right quality,

      • in the right quantity,

      • at the right price,

      • from the right source and

      • at the right time.


    Objectives cond
    Objectives consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Keep the department expense low.

    • Development of good suppliers

    • Development of good relations with suppliers

    • Development of personnel.

    • Development of good records

    • Favorable reciprocal relations

    • Participating in development of new materials and products


    Objectives cond1
    Objectives consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Economic make or buy

    • Standardization

    • Product improvement

    • Interdepartmental relations

    • Forecasts

    • Expansion of business by acquisitions

    • Regulating inventory

    • Cutting operating cost


    Place of material department
    Place of material department consumers and customers, available technology and logistics challenges and opportunities.

    • The place of materials department in any industry is quite equally placed to the important department like design department, manufacturing department etc.

    • Every department has dealing and concern with the materials department.

    • As the department in contact with the outside world the suggestions for the departments in the organization.


    Place of material department in the organization
    Place of material department in the organization consumers and customers, available technology and logistics challenges and opportunities.

    Marketing department

    Engineering department

    Production department

    Manufacturing shops

    Materials department

    Product design

    Industrial engineering

    personnel

    Plant management


    Functions of materials management
    Functions of materials management consumers and customers, available technology and logistics challenges and opportunities.

    • Production department indicates what material is required.

    • Design department indicates what is required.

    • Quality control department checks what is required

    • To achieve the goals and the objectives of the materials department the functions of materials management are as follows


    Functions cond
    Functions consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Make or buy the subassemblies and component.

    • Facilities procurement

    • Calculating quantities for scheduling

    • Ordering of materials

    • Packing the finished goods and storing and dispatch

    • Distribution of material

    • Inventory control activity


    Function cond
    Function consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Material movement

    • Participation in the product development

      • Cost estimates

      • Using standard components

      • Manufacturability of the components

      • Supplier development

      • Guiding design decisions

      • Introducing new materials

    • Functions in Non=manufacturing organization


    Advantages of integrated materials management
    Advantages of integrated materials management consumers and customers, available technology and logistics challenges and opportunities.

    • Better accountability

    • Better coordination

    • Better performance

    • Adaptability of EDP (Electronic Data Processing system)

    • Miscellaneous advantages like

      • Team sprit

      • Opportunities for growth and development


    Unit 9

    UNIT 9 consumers and customers, available technology and logistics challenges and opportunities.

    PURCHASE ORGANIZATION


    Introduction4
    Introduction consumers and customers, available technology and logistics challenges and opportunities.

    • The purchase is a main activity in the area of materials management.

    • It is the most important function in any organization.

    • It decides the profitability of the company

    • It is proved that 1% saved in the purchase function improves the profit of the company as much as 2% to 3%.


    Principles of purchase seven r s
    Principles of purchase (seven consumers and customers, available technology and logistics challenges and opportunities.r’S)

    • Buying the material at right price.

    • Buying materials of right quality.

    • In the right quantity.

    • At the right time.

    • From the right source.

    • At the right place.

    • With right mode of transport


    Objectives of purchase department
    Objectives of purchase department consumers and customers, available technology and logistics challenges and opportunities.

    • To procure at the lowest possible cost consistent with quality and service requirements.

    • If the quality of the company’s product is decided by the quality of the input material then this is the area, where the quality begins.

    • The purchase activity plays important role in keeping the production line flowing.

    • Purchase department controls the inventory control activity.


    Objectives cond2
    Objectives cond.. consumers and customers, available technology and logistics challenges and opportunities.

    • It integrates the requirements of all department of the company.

    • Help the design and development departments to develop new products and related new components of those products.

    • To develop good and continuing vendor relationships.

    • To train and develop highly competent personnel who are motivated to make the company as well as their department succeed.


    Organization of purchase
    Organization of purchase consumers and customers, available technology and logistics challenges and opportunities.

    • Organization by function.

      • Processing of purchase needs.

      • Sending out enquiries.

      • Negotiating with the vendors and selection of suppliers.

      • Preparation of purchase orders.

      • Receipt of material, inspection and storing.

      • Dealing with accounts section.

      • Maintenance of records.

    • Organization by product.

    • Organization by location.

    • Organization by process.


    Methodology of evaluation of purchase department
    Methodology of evaluation of purchase department consumers and customers, available technology and logistics challenges and opportunities.

    • Cost – purchase comparison

      • Annual cost of purchasing department divided by the total value of purchase.

    • Cost per order

      • Total purchasing department cost divided by the number of orders.

    • Return on investment

      • Net savings per rupee spent on purchasing.

    • Quality criteria

      • Measured by the number of rejects.

    • Quantity criteria

      • Measured by downtime.


    Functions of purchase department
    Functions of purchase department consumers and customers, available technology and logistics challenges and opportunities.

    • Activities of placement of order

      • Analyzing quotations received from different vendors.

      • Planning and scheduling purchases and deliveries of the item to avoid excess inventory.

      • Issuing proper purchase orders to the vendor.

      • Selecting capital equipments.

      • Negotiate prices with the vendor before order is placed.

      • To get the item at right price.

      • Checking and approving invoices


    Functions cond1
    Functions consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Purchase records

      • Vendor registration files

      • Closed purchase orders

      • Open purchase orders

      • Material record

      • Imported items record

      • Different law codes of purchase , sales tax, octroi laws, import duty, etc..


    Functions cond2
    Functions consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Purchase reports

      • The budget to be made before the year starts for expenditure under different heads.

      • Total expenditure done for different types of purchase.

      • Purchase value for major items.

      • Purchases made for each planning department.

      • Revisions of budget proposals for running year.

      • Vendor performance report

      • Inventory and consumptin pattern of materials

      • Pattern of market prices.

      • Development of new components for new products.


    Functions cond3
    Functions consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Maintenance of vendor relations

      • Communication of essential and helpful information, design, specifications, standards, practices etc.

      • Communication of engineering changes and changes in specifications etc.

      • Developing methods for detecting deviations from standards

      • Helping the vendor in resolving quality problem.

      • Providing for use of vendor quality data during inspection.

      • Developing methods for identifying the qualified vendors.


    Functions cond4
    Functions consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Maintenance of vendor relations cond…

      • Reviewing the performance of the vendor through vendor rating.

      • The guiding principle in vendor relations is the sprit of what best for the partnership.

    • Forecasting and planning.

    • Selection of best vendors

    • Fixing price, checking invoices

    • inspection


    Role of purchase in total customer satisfaction
    Role of purchase in total customer satisfaction consumers and customers, available technology and logistics challenges and opportunities.

    Engineering

    Marketing

    Stores

    Quality

    Legal

    Manufacturing

    Purchase

    Product design

    Account/finance

    Information system

    Logistics

    Top Management

    Personnel


    Unit 10

    Unit 10 consumers and customers, available technology and logistics challenges and opportunities.

    Procurement Procedure and Policy


    Procedures in purchase department
    Procedures in purchase department consumers and customers, available technology and logistics challenges and opportunities.

    • There are steps in which a purchase transaction is carried through from its inception to its conclusion.

    • Since there are wide variations among industries, companies, organizations, products and personnel, there will be some slight deviation in the procedure to suit the particular set up of the company.

    • The procedure of the purchase is shown as per the flow chart shown in the figure below.


    Requirement form user department consumers and customers, available technology and logistics challenges and opportunities.

    Send ENQUIRT to the vendors

    Get QUOTATION from vendors

    Study and compare the quotations with our estimated cost

    Procedure in purchase functions

    Negotiate the quotation to fix the price

    Place the ORDER to the right vendor

    Follow up with vendor

    Get the material

    Inspect the material

    Stores credit the material


    Purchase cycle
    Purchase cycle consumers and customers, available technology and logistics challenges and opportunities.

    Follow up

    supplier

    Other user department

    PO request

    PO Acceptance

    PO

    enquiry

    Purchase department

    quotation

    Inspection reports

    PO

    payment

    PO

    goods

    Stores department inventory control

    Accounts department

    Inspection reports


    Purchase cycle cond
    Purchase cycle consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Purchase requisition

    • Request of quotation (Enquiry)

    • Purchase order

    • Planning and follow-up

    • Receiving and inspection


    Purchase policy
    Purchase policy consumers and customers, available technology and logistics challenges and opportunities.

    • For proper working, perfect guidelines and policy is required.

    • The purchase policy keeps good transparency for vendors who are regularly interacting with the company.

    • The purchase policy should conver important subjects like quality, inventory, price, credit to vendor, payment system to vendor etc..


    Contents of operating policies
    Contents of operating policies consumers and customers, available technology and logistics challenges and opportunities.

    • Policies include the following points:

      • Pricing policies

      • Quality of materials

      • Policies of inventory management

      • Selecting suppliers, their properties


    The policy manual
    The policy manual consumers and customers, available technology and logistics challenges and opportunities.

    • A policy manual has 2 distinct sections:

    • Company policies:

      • This indicates the terms, the responsibility and authority of the purchase department different, as the responsibility and authority of all other departments.

      • It is essential that policies carry top management approval and that they become responsibility to every department head.


    The policy manual cond
    The policy manual consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Department policies:

      • Has complete guidelines for the purchase department operations

      • Transportation and price

      • Discounts

      • Petty cash purchases

      • Employee purchases

      • Vendor payment

      • Ethics

      • procedures


    The policy manual cond1
    The policy manual consumers and customers, available technology and logistics challenges and opportunities.cond…

    • Producers:

      • Receipt

      • Inspection

      • Invoices

      • Receiving and storage

      • Surplus and scrap disposal

      • Transportation

      • Purchases for employees

      • Records and reports

        • Departmental records

        • Internal reports

        • External reports


    Unit 11

    UNIT 11 consumers and customers, available technology and logistics challenges and opportunities.

    VENDOR DEVELOPMENT AND EVALUATION


    Searching for a good supplier
    Searching for a good supplier consumers and customers, available technology and logistics challenges and opportunities.

    Suppliers are found through following ways:

    Inviting quotations

    Purchasing directories

    Catalogue and vendor files

    Through magazines

    Through personal contacts with suppliers, salesman or other buyers


    Suppliers requirements to be a good supplier
    Suppliers requirements to be a good supplier consumers and customers, available technology and logistics challenges and opportunities.

    • Facilities to fulfill the orders received

    • List of equipment

    • Plant visit

      • Is the equipment up to date?

      • Is there effective material control?

      • Is the plant well lighted and well ventilated and that has guards on machines to prevent accident?

      • What are the suppliers fire protection facilities?

      • Does the supplier has the equipment to handle the buyer’s order?

      • If the supplier has efficient receiving and dispatching facilities

        con…


    Suppliers requirements con
    Suppliers requirements con… consumers and customers, available technology and logistics challenges and opportunities.

    Personnel

    Financial resources

    Reputation

    Assistance to suppliers from the company for satisfactory quality.

    Is vendor registered?


    Vendor evaluation
    Vendor evaluation consumers and customers, available technology and logistics challenges and opportunities.

    • It is required to measure the performance of the vendor.

    • The work of purchase dept. is to establish procedure and system for vendor rating.

    • Factors for rating of vendors are as follows:

      • Financial capability

      • Technical capability

      • Morale of employees

      • Lead time required to supply the item

      • Motivation for serving the buyer’s firm before and after the supply.

      • Managerial ability

        con…


    • Cost controlling ability consumers and customers, available technology and logistics challenges and opportunities.

    • Type of machinery in the plant, condition, maintenance

  • Objectives of rating:

    • Reviewing the orders for better profitability

    • Comparing the placement of the order

    • Selecting vendors for new product development or changing the suppliers for running product for better results.

  • Vendor performance rating:

    • The standards can be based on past performance of the vendor.

      • For quality

      • For service

      • For price


    • For Vendor rating the following questions can help: consumers and customers, available technology and logistics challenges and opportunities.

      • Reliability in all the fields like

        • Is the supplier reputable, stable an financially strong?

        • Is the supplier going along with product improvement?

      • Technical capabilities of vendor like

        • Can the supplier provide assistance to application engineering?

        • Can the supplier provide assistance to design engineering?

      • Convenience to deal with, say,

        • Can the supplier offer other related products or materials?

        • Is the supplier qualified to help in solving difficult problems like reducing acquisition costs through personal visits, telephone calls rejection of defects etc.?

      • Delivery index like

        • Does the supplier assure delivery in time?

        • Can the supplier plan his supply to minimize inventory?

        • Can the supplier be depended on for a steady flow of materials?


    • After sales services like consumers and customers, available technology and logistics challenges and opportunities.

      • Does the supplier have a service organization?

      • Is an emergency service available?

      • Are parts available when needed?

    • Sales assistance like

      • Can the supplier help building mutual markets?

      • Will the supplier recommend our products?

      • Does the use of suppliers product enhance appearance of out product?

  • Vendor evaluation:

    • Evaluating the performance before the vendor has delivered anything. (called ad vendor evaluation)

    • Evaluating the performance after the vendor has delivered the materials. (called ad vendor monitoring)

    • The evaluation also includes

      • General reputation of vendor

      • Historical information from other buyers

      • Vendor surveys


    • Evaluation by quality rating: consumers and customers, available technology and logistics challenges and opportunities.

      • Q = total quantity supplied

      • Q1 = quantity accepted

      • Q2 = quantity accepted with concession

      • Q3 = quantity accepted with rectification

      • Q4 = quantity rejected

    • Q = Q1 +Q2 + Q3 + Q4

    • Quality rating = [(Q1 + Q2 + Q3)/Q] * 100

  • Evaluation by price rating:

    • Rp = [(lowest price quoted / price agreed by vendor)] * 100

  • Evaluation by delivery rating:

    • Rd = [(promised delivery time / actual delivery time)] * 100


    • Evaluation by service rating: consumers and customers, available technology and logistics challenges and opportunities.

      • Service rating is judgment on the basis of following 5 points:

        • S1 = readiness to help in emergencies

        • S2 = readiness to replace rejected materials

        • S3 = providing support documents in time

        • S4 = promptness in reply

        • S5 = acceptance of terms without complaints

      • Where S1 + S2 + S3 + S4 + S5 = 100

    • The cost ratio plan:

      • It includes 3 cost ratio such as

      • Quality cost ratio – includes relative cost of quality.

      • Delivery cost ratio – includes relative cost of placing and receiving an order.

      • Service cost ratio – includes technical, managerial and field service competence of the vendor.


    Cost elements

    Cost Elements consumers and customers, available technology and logistics challenges and opportunities.

    UNIT 13


    Cost estimation process
    Cost estimation process consumers and customers, available technology and logistics challenges and opportunities.

    • The cost estimating system is used to find the following major components:

      • Direct – material cost

      • Direct – operation cost

      • Overheads

        • Manufacturing overhead

        • Administrative overhead

      • Other expenses like taxes etc.


    Direct material cost
    Direct material cost consumers and customers, available technology and logistics challenges and opportunities.

    • It includes any purchased part or material that is used directly in the product.

    • it is the one, which goes in to the component of the product.

    • In-direct material cost

      • Are those which are consumed for the processing like lubricating oil or the cutting oil without which the production process is not possible or the process performance or tool efficiency improves.

      • All maintenance, repair and operating supplies are considered indirect cost and are part of the manufacturing overhead.

      • They are not directly incorporated into the product.


    Direct operational cost
    Direct operational cost consumers and customers, available technology and logistics challenges and opportunities.

    • This is called direct labor cost.

    • Errors are made even more frequently in estimating labor costs.

    • Direct labor cost includes all work performed directly on the component which includes machine operations.

    • The operations like inspection, materials handling, maintenance, supervision are some of the indirect operational cost


    Overheads
    Overheads consumers and customers, available technology and logistics challenges and opportunities.

    • These are companies expense, which are the type of fixed expenses.

    • It is of 2 types

      • Manufacturing overheads

        • Expenses associated with factory supplies, indirect labour, depreciation and so on.

      • Administrative overheads

        • Expenses associated with office clerical and executive salaries, office supplies, rent and so on.

    • These overheads can be either

      • Fixed overheads

      • Variable overheads


    Other expenses
    Other expenses: consumers and customers, available technology and logistics challenges and opportunities.

    Some of these are also considered as overheads:

    • Excise duty

    • Sales tax (SST)

    • Sales tax (CST)

    • Octroi

    • Dispatching charges (for transport)

    • Handling charges

    • Insurance

    • Vendor’s surcharge


    Economic order quantity eoq just in time jit

    ECONOMIC ORDER QUANTITY (EOQ) & JUST IN TIME (JIT) consumers and customers, available technology and logistics challenges and opportunities.

    UNIT 14


    Ordering quantity levels
    Ordering quantity levels consumers and customers, available technology and logistics challenges and opportunities.

    • EOQ formula

      • Let us assume

      • A = Annual consumption

      • Q = Order Quantity

      • B = Cost per order

      • C = carrying cost per cent

      • P = price per unitT = total ordering and carrying cost

    • Total inventory cost = ordering cost + inventory carrying cost

      • T = (A/Q) * B + (Q / 2) * P * C

    • Solving above to economic order quantity Q

      • Q = sqrt [2BA /( P * C)]


    Use of eoq methodology
    Use of EOQ methodology consumers and customers, available technology and logistics challenges and opportunities.

    • Reasonable steady and predictable usage

    • Relatively low cost

    • Short lead – time


    Just in time jit
    Just In Time (JIT) consumers and customers, available technology and logistics challenges and opportunities.

    • This is a technique from TQM activity

    • Basically this is waste control method.

    • It is not the inventory control method.

    • It is organized approach to introduce in manufacturing cycle

      • Timeliness

      • Quality

      • Productivity

      • Flexibility

      • Work simplification and waste reduction


    Waste reduction problems
    Waste reduction problems consumers and customers, available technology and logistics challenges and opportunities.

    • The waste reduction exposes problems in organizations like

      • Improper methods

      • Waiting or delays

      • Machine or system breakdowns

      • Rejections or rework

      • Low demand for product in markets

      • Poor supervision



    Techniques used in jit
    Techniques used in JIT problem

    • Kanban – an integrated JIT system

    • SMED – Single digit Minute Exchange Die

    • JIDOKA

    • Poka yoke


    Kanban an integrated jit system
    Kanban problem – an integrated JIT system

    • It was developed at Toyota in the 1950s as a way of managing material flow on the assembly line, and identifies as ‘ a highly efficient and effective factory production system.

    • Kanban process involves more than JIT deliveries and inventory control.

    • Its concept is that a suppler or the warehouse should only deliver components to the production line as and when they are needed, so that there is no storage in the production area.


    Advantages of kanban process
    Advantages of problemKanban process

    • A simple and understand process.

    • Provides quick and precise information

    • Low costs associated with the transfer of information

    • Provides quick response to change

    • Limits the over capacity in processes

    • Avoids over production

    • Minimizing the waste

    • Control can be maintained

    • Delegates responsibility to the workers


    Group technology
    Group technology problem

    • This contributes to the efficiency of kanban.

    • This is modular manufacturing, which involves organizing machinery so that related products can be manufactured in a continuous flow.

    • The secret of the kanban’s success is its requirements that each part of an organization be totally interdependent management and workers believe that productivity and quality come form people rather than systems.


    Advantages of gt
    Advantages of GT problem

    • Number of new parts are less

    • Any new part required are designed to suit the manufacturing.

    • Manufacturing standards are set, so that just some minor modification is to be done for new process plan rather than buying new tools.

    • Set up time is reduced.

    • Flexible manufacturing systems and computer aided manufacturing.


    S m e d technique
    S M E D Technique problem

    • It stands for Single Minute Exchange of Die.

    • It is a theory and techniques for performing setup operations in fewer than ten minutes, i.e., in number of minutes expressed in a single digit


    Methodology adopted
    Methodology adopted problem

    • Form the setup time reduction team.

    • Conduct training and education.

    • Study the setup process ( manual, video tape)

    • Classify setup operations into waste, internal setups and external setups.

      • Waste – operations which do not add values to setup.

      • Internal setup – operations that can only be performed while the machine is shut down. This is basically to be reduced.

      • External setup – operations that can be performed without shutting down the machine.

    • Eliminate the waste



    Jidoka automation
    JIDOKA ( Automation) setups.

    • It is a concept of adding an element of human judgment to automated equipment.

    • By this the equipment can identify unacceptable items and the automated process becomes more reliable.

    • Objective:

      • Ensuring quality 100% of the time.

      • Preventing equipment breakdowns.

      • Using manpower efficiently.


    Poka yoke mistake proofing
    Poka setups. yoke (Mistake Proofing)

    • The principles of poka yoke advocate designing or developing tools, techniques and processes such that it is impossible or very difficult for people to make mistakes.

    • Ti is simple principle that can lead to massive savings.

    • This principle was invented in the year 1960 by Japanese.


    8 principals of improvement by pokayoke
    8 principals of improvement by setups.Pokayoke

    • Build quality in processes

    • All inadvertent errors and defects can be eliminated.

    • Stop doing wrong and start doing right

    • Don’t think of excuses. Think about how to do right

    • 60% chance of success is good enough. Implement idea now.

    • Mistakes and defects can e reduced to zero when every one works together to eliminate.

    • Ten heads are better than one.

    • Seek out true cause using 5Ws and one H.

      [ why , when , who , where , what and how ]


    Application of poka yoke
    Application of setups.Poka - Yoke

    • Manual operations where worker vigilance is needed.

    • Where misalignment can occur.

    • Where adjustment is required.

    • Where teams need common – sense tools.

    • Where attributes not measurements are important.

    • Where mixed model production occurs.

    • Where training costs and employee turnover are high.



    The purchase functions
    The purchase functions setups.

    The computer characteristics are as follows

    • High speed

    • Large storage

    • Quick processing of the data

    • Quick retrieval

    • Accuracy in calculations

    • Flexibility in working


    Things best done by computers
    Things best done by computers setups.

    • Determining economic lot size of each item.

    • Determining safety stock level.

    • Determining ordering level ad reorder level.

    • Inventory file for each item.

    • Inventory analysis.

    • List of the suppliers along with their rating

    • Master purchase file condensing the previous purchases

    • etc..


    Reports prepared by the system
    Reports prepared by the system setups.

    Some of the reports that save time are

    • Inventory master details

    • Category of the item

    • Items not supplied in time

    • Items rejected or accepted

    • Excess supplies done by the vendor

    • Etc..


    Mrp concept
    MRP concept setups.

    • 1970 was the period when they invented the Material Requirement Planning (MRP).

    • MRP utilizes s/w applications for scheduling production processes.

    • MRP s/w generates schedules for the operations and the raw material purchases based on the production requirements of finished goods, the structure of the production system the current inventories levels etc.

    • MRP asks the following questions:

      • What products are we going to make?

      • What are the materials needed to make the products?

      • What are the materials that we have in stock?

      • What are the items that need to be purchased?


    Sales setups.forecost

    Customer order

    Product design

    Inventory trans.

    Mngt. policy

    Master schedule

    Bill of materials

    Inventory records

    MRP software

    input

    output

    Production orders

    Purchase request

    Management reports


    Advantages of mrp
    Advantages of MRP setups.

    • Reduced inventory levels

    • Reduced shortages of components

    • Better manpower planning

    • Improved shipping schedules

    • Better customer service

    • Reduced purchase cost

    • Improve production schedules

    • Reduction in lead times

    • Improved quality products


    Problems in MRP implementation setups.

    • Need of high level of discipline

    • The procedures in the company have to be clear

    • Cost of software is high and further implementation is costly


    Different modules of mrp
    Different modules of MRP setups.

    • Accounting

    • Inventory program

    • Production control and planning

    • Purchasing

    • Receiving

    • Manpower planning

    • Sales and logistics

    • Invoicing

    • warehouse


    Inventory concepts

    Inventory concepts setups.

    UNIT 17


    Analyzing inventroy
    Analyzing setups.inventroy

    • ABC Analysis

    • VED Analysis

    • XYZ Analysis


    Abc analysis
    ABC Analysis setups.

    • The basic of “ABC” approach to inventory control, which provides maximum overall protection against stock outs for a given investment in safety stocks.

    • The high value items have lower safety stocks because the cost of the protection is high.

    • The low value items have higher safety stocks because the cost of the protection is low.



    • Inventories are divided into 3 classes: in inventory and multiply this by unit cost to determine value of usage.

      • A category items account for 10 % items for roughly 70% of the value.

      • B items for 20% of the total and about 20% of the value.

      • C items for 70% of the total and about 10% of the value.


    Ved analysis
    VED Analysis in inventory and multiply this by unit cost to determine value of usage.

    • V – stands for vital items

    • E – stands of essential items

    • D – stands for desirable items


    • Vital items are the most critical having extremely high cost of shortage and must be available in the stock when demanded.

    • Essential items are quite critical with substantial cost associated with shortage and should be available in stock by and large.

    • Desirable items do not have very serious consequences if not available when demanded but can be stocked items


    • The classification of items should be done in 9 groups such as

      A + V B + V C + V

      A + E B + E C + E

      A + D B + D C + D

    • For each of these 9 categories the inventories can be planned as FSN analysis

      • F – stands for fast moving items

      • S – stands for slow moving items

      • N – stands for non moving items (deadlocks)


    Xyz analysis
    XYZ Analysis as

    • In any company it is difficult to forecast the quantity for each item accurately.

    • The forecast ability is identified by “XYZ” analysis.

    • “X category” items are those which can be accurately forecasted.

      • These are about 20% of the total items.

    • “Y category” items are those which are less accurately forecasted.

      • These are about 50% of the total items.

    • “Z category” items are those which can be least accurately forecastable.

      • These are about 30% of the total items.



    Functions of warehouse
    Functions of warehouse as

    • Receive the material

    • Store the material properly

    • Mixing of material

    • Remove the material when required

    • Deliver the material to right place

    • Keep the records perfectly in discipline

    • Packing and waiting for the order

    • Maintaining good housekeeping

    • Keep proper control

    • Manage the people in perfect discipline

    • Avoid keeping surplus material

    • Verification of stocks at regular interval

    • Coordination and cooperation

    • Arranging transport


    Warehouse organization
    Warehouse Organization as

    President

    Material manager

    Production manager

    Marketing

    Movement

    Purchase

    Warehouse

    Office

    Receiving

    Finished goods

    Transport


    Warehouse layout and design
    Warehouse layout and design as

    • Considerations for layout:

      • How well does the store meet the needs of its customer?

      • Is appropriate technology being used?

      • How well are the resources utilized in the store?

      • How manageable is the store?

      • How flexible is the store?


    • Resource of the warehouse as

      • The space

      • The equipment

      • The information

      • The manpower.

    • Factors for warehouse design:

      • The type of material to be stored.

      • The variety of material stored.

      • The speed at which the material has to move.

      • The location of suppliers

      • The location of customers


    A good layout must be as follows: as

    • To achieve minimum waste of space and flexibility of arrangement

    • Supplying right material to customer as and when required.

    • Ensure easy movement of the material handling equipments.

    • Minimize of material handling requirements.

    • Minimize of material deterioration (wasting).


    Factors to be considered for layout and design
    Factors to be considered for layout and design as

    • The space for receipt and inspection should be provided adjacent to the main warehouse.

    • Clear markings should be made at the storage space to facilitate location and identification.

    • The layout should permit the use of modern material handling equipments.

    • Due space should be left for expansion purpose in each portion.

    • A pleasing and hygienic environment must be provided within the warehouse.

    • Adequate and clear lighting arrangement should be provided.


    Warehouse ownership
    Warehouse ownership as

    • Owned by company:

      • The company has its own warehouse

      • There is no restriction for keeping any material that company desires.

      • All the arrangements, facilities and design are done as per the needs of the company.

    • Rental warehouse

      • There are logistic companies who keep the warehouse on rent.

      • There are no capital expenses by the company like land cost, construction etc.

      • The arrangement can be kept for some specific period, if needed thereafter can be extended or closed.


    Types of warehouses
    Types of warehouses as

    • Private warehouse

      • It is owned and operated by a company for the aspects of the distribution and storage of products.

    • Public warehouse

      • It is essentially space that can be leased to solve short term distribution needs.

    • Automated warehouse

      • This warehouse have automated capabilities like conveyor belt for transporting products to a fully automated facility where only a few people are needed to handle storage activity for thousands of products.


    • Climate – controlled warehouse as

      • It handles products which needs handling conditions such as freezers for storing frozen products, humidity – controlled environment for delicate products like flowers and dirt – free facilities for handling sensitive computer products etc..

    • Distribution center

      • It is where product storage is considered a very temporary activity.

      • It serve as center of distribution system at which products are received from many suppliers and quickly shipped out to many customers.

    • Storage warehouse

      • It store product for periodic delivery to a manufacturer or distribution center.

      • This is often associated with providing JIT delivery.


    • Cross docking and trans-loading warehouse as

      • It provide cross dock and trans – loading services.

      • These services require temporary storage for a grace period.

    • Value added services

      • It provide a wide range of value added services.

      • The services like labour, special equipment to the customers product, like repackaging, labeling, etc..

    • Break bulk warehouses

      • It receive product in bulk and then repackage the product based on customer requirements.

    • Fulfillment / consolidation warehouse

      • It is where products are generally received in large quantities and shipped out in a large number of smaller mixed shipment.



    Inbound and outbound movement of material handling
    Inbound and outbound movement of material handling as

    • Definition:

      • In any organization the activity of transferring of goods in and out moving goods in various locations in the warehouse is called inbound and outbound movement.

    • Characteristics of material handling:

      • Speed – movement between the production unit and different warehouse.

      • Time – relates to period required for the material handling activities.

      • Quantity shifted – takes care of the amount of material moved between the places

      • Space - indicates the effective utilization of the available space in the warehouse


    Objectives of material handing
    Objectives of material handing as

    • Improve logistics management.

    • Space capacity of production as well as warehouse should be increased.

    • Reduce the number of handlings of the material.

    • Develop good working conditions (safe and secured).

    • Reduce manual handling of the material.

    • Cost reduction has to be achieved.


    Principles of materials handling
    Principles of materials handling as

    • Plan well the needs, performance objectives and functional specifications.

    • Standardization of material handling methods, equipment controls etc..

    • Minimize the work

    • Selection of equipment

    • Training for operation of new equipments

    • Adaptability of the equipments for variety of jobs

    • Unit load for free flow of material and inventory


    • Maintenance of the equipments as

    • When new improved handling system is brought, then remove the old one by one to keep up the efficiency of operations.

    • Systematic coordination of receiving, keeping and dispatching the operating systems.

    • Appropriate automation reduce human unsafe manual labour operations.

    • Smooth flow of materials

    • Ensure safety of all operations for working persons as well as materials.

    • Controls are used to improve the order fulfillment, production and inventory.


    Equipments used for material handling
    Equipments used for material handling as

    • The equipments used in storeroom are :

      • Storing equipments

      • Material handling equipments

    • Selection of different equipment is a key to the successful operations of a storeroom.


    Common storeroom equipments
    Common storeroom equipments as

    • Cabinets

    • Stacking boxes

    • Special storage racks

    • Gravity feed racks

    • Outdoor platforms and racks

    • Open and closed shelves

    • Trays

    • Drums

    • Barrels pallets

    • Tote boxes – loose parts of the materials between operations

    • Wire bins loose parts of the materials in inventory


    Material handling equipments
    Material handling equipments as

    • Manual material handling

    • Manual equipments

    • Mechanized systems

    • Automated systems


    Manual material handling systems
    Manual material handling systems as

    • Trolleys

    • Monorails

    • Belt conveyor

    • Roller conveyor

    • Crane

    • ladders


    Manual equipments
    Manual equipments as

    • Hydraulic scissor lift tables

    • Stackers and portable cranes

    • Manual stacker

    • Hydraulic pallet trucks

    • Pallet trucks

    • Pallet trucks

    • Caster wheels

    • Fork lift truck


    Mechanized systems
    Mechanized systems as

    • Conveyors

    • Rollers

    • Cranes

    • Turntables

    • Trucks


    Packing
    Packing as

    • Purpose of packing

      • The product should be protected from environment abuses till the time it reaches to the real customer.

      • Ease of handling the product is provided in the packing.

      • Efficient packaging help reduce the need to unpack and repack the products.

      • Instigating packaging design through engineering helps to attract customers

      • Developing universal packaging and pallet design can be used for number of different products.


    Packing cost
    Packing cost as

    • The packing cost comprises of

      • Material cost

      • Labour cost

      • Packaging equipment like machines, tables, tools fixture

      • Space and place for operations of packing


    Packing materials
    Packing materials as

    • The generally used materials for packaging:

      • Adhesives, fasteners, nails,

      • Containers, cartons, boxes, bags,

      • Wood, steel, plastic labels,

      • Tapes of different types, ropes, drums,

      • Specially shaped molded thermocol boxes,

      • Heat sink plastic bags,

      • Plastic spray to protect product from dust,

      • Crates to carry bottles in unitized way,

      • Pallets, bubble wrap, refuse sacks, strapping.



    Network design
    Network design as

    • The distribution involves the methods of transportation, with the combined effect of the IT and contribution of different s/w used as per the product.

    • When designing the logistics n/w, the strategic factors are to be determined to find the level of customer service.

      • Speed to market (time taken by the product to reach the market so that it can be delivered to customer)

      • Economic factors such as taxes and exchange rates.

      • Infrastructure such as water, electricity, transportation routes etc.

      • Logistics cost and network size.


    Functions of distribution
    Functions of distribution as

    • It is the internal service function for any firm

    • The distribution n/w is basically the infrastructure through which material, information and finances flow between suppliers, manufactures, distributors, transports, retailers and the customers.


    Distribution channels
    Distribution channels as

    • It represents the channel through which products or materials or services reach customers.

    • A single distribution channel can be assigned to one or more sales organizations

    • Eg. Wholesale, retail, direct sales etc..



    Factors for selection of location
    Factors for selection of location as

    • Land

    • Manufacturing facility

    • Taxation and regional concessions

    • Access to transport

    • Power / fuel / energy

    • Water / climate

    • Availability of work force


    Factors for selection of location1
    Factors for selection of location as

    • Union activities

    • Political pressure

    • Banks and finance facilities

    • Raw materials

    • Safety and social security

    • Supporting industries

    • Market site

    • People culture and environment


    Information system

    Information system as

    UNIT 22


    Definition
    Definition as

    • Information System is an interacting structure of people, equipment, and procedures that together make relevant information available to the supply chain manager for the purpose of planning, implementation, and control.


    Functions of information
    Functions of information as

    • Take proper decision at all levels in the organization.

    • Provide database at appropriate stage.

    • Support planning functions.

    • Provide controls in the operations.

    • Communication with concerned persons.


    Forms of information
    Forms of information as

    • Written form

    • Charts

    • Graphs

    • Columns sheets

    • Black board

    • Hoardings – very important information (1 line statement )

    • Verbal or telephonic


    Attributes of information
    Attributes of information as

    • Real time information

    • Accuracy

    • Regular availability

    • Relevant to right person


    Technologies for is
    Technologies for IS as

    • Internet connectivity

    • E – Commerce

    • S/w tools

    • Bar coding / scanning

    • EDI – Electronic Data Interchange

    • XML – Extensible Markup Language

    • Data management and imaging

    • RF (radio frequency) technology

    • Artificial Intelligence

    • Expert system

    • Knowledge management


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