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Tech Supply Chain Associates. Final Presentation. Milliken Asia Group II. April 25 2006. Rakshita Agrawal, Vishal Agrawal Aditya Dhanrajani, Michael Liebmann Uttam Malani, Jenny Zhang. Outline. A Project Overview B The Model C Results. Demand. Supply. Tokyo. Osaka.

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Presentation Transcript
slide1

Tech Supply Chain Associates

Final Presentation

Milliken Asia Group II

April 25 2006

Rakshita Agrawal, Vishal Agrawal

Aditya Dhanrajani, Michael Liebmann

Uttam Malani, Jenny Zhang

Project Presentation April 18 2006

outline
Outline

A Project Overview

B The Model

C Results

Project Presentation April 18 2006

project overview

Demand

Supply

Tokyo

Osaka

Melbourne

Seoul

Auckland

Bangkok

Shanghai

Beijing

Chennai

Taipei

Mumbai

Ho Chin Minh

Sydney

Jakarta

Project Overview

Kolkata

Hong Kong

Manila

Spartanburg

Kuala Lumpur

Project Presentation April 18 2006

problem definition
Problem Definition

Collect Data

Inventory

Analysis

Location

Decision

Determine Locations by minimizing overall costs

Decision Based on Safety Stock and Service Level

Project Presentation April 18 2006

demand data overview

Red & black

5

10

5

Red

5

5

10

Total number of cases

20

2 Periods x 2 Product sets x 5 Scenarios = 20 Cases

Demand Data Overview

A2005

E2010

Σ

Project Presentation April 18 2006

demand distribution and forecast

Estimated change in product demand

2005

2010

4m

3m

2m

1m

Red

Red

Red & Black

Red & Black

Strong growth projection more impact on profits

Demand distribution and forecast

Project Presentation April 18 2006

outline1
Outline

A Project Overview

B The Model

C Results

Project Presentation April 18 2006

assumptions

2

Leasing rather than building warehouses

( no capacity constraint)

3

No warehouses in India

Assumptions

List of Assumptions

1

Local demand consolidated in demand cities and ports

Project Presentation April 18 2006

the model

Transportation cost

Pipeline inventory cost

WH leasing cost

ai

cj

xij

xij

e

xij

bj

ai

ai

Dij

Decision variable

Demand at point i

Est. leasing cost at j

Pipeline cost at j

Demand at point i

Decision variable

Decision variable

Demand at point i

Est. transport cost

Distance bn. i and j

i

Set of demand centers

j

Set of warehouses

The Model

Min [ Σi Σj e ai Dij xij + ΣiΣjai bj xij + ΣiΣjai cj xij ]

Project Presentation April 18 2006

port accessibility factor
Port Accessibility Factor

Routing example #1

Project Presentation April 18 2006

port accessibility factor1
Port Accessibility Factor

Routing example #2

Project Presentation April 18 2006

outline2
Outline

A Project Overview

B The Model

C Results

Project Presentation April 18 2006

location mapping scenario red black 2005

Tokyo

Osaka

Taipei

Seoul

Auckland

Bangkok

Melbourne

Shanghai

Beijing

Ho Chin Minh

Mumbai

Chennai

Jakarta

Sydney

Location MappingScenario: Red & Black 2005

Scenario #1: I WH

Kolkata

Hong Kong

Manila

Kuala Lumpur

Project Presentation April 18 2006

location mapping scenario red black 20051

Tokyo

Osaka

Ho Chin Minh

Auckland

Melbourne

Shanghai

Beijing

Mumbai

Chennai

Jakarta

Sydney

Location MappingScenario: Red & Black 2005

Scenario #2: II WHs

Seoul

Kolkata

Taipei

Hong Kong

Manila

Bangkok

Kuala Lumpur

Project Presentation April 18 2006

location mapping scenario red black 20052

Tokyo

Osaka

Sydney

Auckland

Melbourne

Shanghai

Beijing

Ho Chin Minh

Mumbai

Chennai

Jakarta

Location MappingScenario: Red & Black 2005

Scenario #3: III WHs

Seoul

Kolkata

Taipei

Hong Kong

Manila

Bangkok

Kuala Lumpur

Project Presentation April 18 2006

location mapping scenario red black 20053

Tokyo

Osaka

Auckland

Shanghai

Beijing

Ho Chin Minh

Mumbai

Chennai

Jakarta

Location MappingScenario: Red & Black 2005

Scenario #4: IV WHs

Seoul

Kolkata

Taipei

Hong Kong

Manila

Bangkok

Kuala Lumpur

Sydney

Melbourne

Project Presentation April 18 2006

location mapping scenario red black 20054

Tokyo

Osaka

Sydney

Auckland

Melbourne

Shanghai

Beijing

Ho Chin Minh

Mumbai

Chennai

Jakarta

Location MappingScenario: Red & Black 2005

Scenario #5: V WHs

Seoul

Kolkata

Taipei

Hong Kong

Manila

Bangkok

Kuala Lumpur

Project Presentation April 18 2006

location matrix for all five cases scenario red black 2005 2010

1

Taipei

Taipei

2

Ho Chin Minh City, Seoul

Bangkok, Shanghai

3

Bangkok, Sydney,

Seoul

Bangkok, Sydney, Shanghai

4

Taipei, Seoul,Bangkok, Melbourne

Taipei, Seoul, Bangkok,Sydney

5

Bangkok, Seoul,

Taipei, Sydney,

Osaka

Bangkok, Seoul ,

Taipei,Sydney

Osaka

Location Matrix for All Five CasesScenario: Red & Black 2005 & 2010

# DCs

2005

2010

Project Presentation April 18 2006

location matrix for all five cases scenario red black 2005 20101

1

Taipei

Taipei

2

Ho Chin Minh City, Seoul

Bangkok, Shanghai

3

Bangkok, Sydney,

Seoul

Bangkok, Sydney, Shanghai

4

Taipei, Seoul,Bangkok, Melbourne

Taipei, Seoul, Bangkok,Sydney

5

Bangkok, Seoul,

Taipei, Sydney,

Osaka

Bangkok, Seoul ,

Taipei,Sydney

Osaka

Location Matrix for All Five CasesScenario: Red & Black 2005 & 2010

# DCs

2005

2010

Project Presentation April 18 2006

service level

Tokyo

Osaka

Seoul

Kolkata

Hong Kong

Bangkok

0-2 days

Kuala Lumpur

2-4 days

4-7days

Sydney

Melbourne

Auckland

Shanghai

Beijing

Chennai

Ho Chin Minh

Mumbai

Taipei

Jakarta

Manila

Service Level

2005 Coverage Radii for 3 WHs

Project Presentation April 18 2006

demand coverage 2005
Demand Coverage 2005

Red & Black 2005

Project Presentation April 18 2006

demand coverage 2010
Demand Coverage 2010

Red & Black 2010

Project Presentation April 18 2006

safety stock considerations
Safety Stock Considerations

Safety Stock Red & Black 2005

Service Level

97%

Lead time

5 weeks

Lead time variability

0.5 week

Project Presentation April 18 2006

conclusions

1

1

Recommendations for location of warehouses & associated inventory levels

Special Economic Zones (SEZ’s) and Free Trade Areas

2

2

Evaluation of scenarios based on projected demand data for 2010

Frequency of shipping from Spartanburg to Asia

3

3

Optimization tool for Milliken to accommodate changing needs and

customer base

Effect of transshipment hubs like Singapore on lead times

Conclusions

Summary

Further Considerations

Project Presentation April 18 2006

thank you

Tech Supply Chain Associates

Thank you

Q&A

Project Presentation April 18 2006

thank you1
Thank you

Backup

Project Presentation April 18 2006

safety stock service level red 2005
Safety Stock & Service LevelRed 2005

Safety Stock Red 2005

Service Level Red 2005

Project Presentation April 18 2006

safety stock service level red black 2005
Safety Stock & Service LevelRed & Black 2005

Safety Stock Red & Black 2005

Service Level Red & Black 2005

Project Presentation April 18 2006

safety stock service level red 2010
Safety Stock & Service LevelRed 2010

Safety Stock Red 2010

Service Level Red 2010

Project Presentation April 18 2006

safety stock service level red black 2010
Safety Stock & Service LevelRed & Black 2010

Safety Stock Red & Black 2010

Service Level Red & Black 2010

Project Presentation April 18 2006

backup slides safety stock calculation
Backup slidesSafety stock calculation

Project Presentation April 18 2006