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This position is a senior appointment within the organisation and will take full responsibility
for driving various projects aimed at strategically improving the supply chain function. The
focus of the projects will vary but will incorporate the full end to end supply chain function
with the aim to increase efficiency, reduce cost and improve the overall delivery percentage
of the function.
Key Objective's
* To perform a full end to end analysis of the supply chain function and identify potential
opportunities and discrepancies in the system
* Develop relationships with both suppliers and clients to fully understand the capabilities
and needs of both respectively in order to accurately understand the supply chain
environment
* To develop a strategic solution for the each identified potential opportunity within the
supply chain function
* Present a final overall plan including all elements of the supply chain strategic
improvement plan to senior management
* Drive cross functional teams to meet goals agreed with senior management
Supply Chain Balanced Scorecard was designed to help in measuring and controlling company
delivery service and associated aspects. This metrics set will help to measure the performance of
manufacturing, warehouse and delivery from various viewpoints, including customer satisfaction
and financial, giving key manager key performance indicators for supply chain business unit.
The metric pack includes such KPI (Key Performance Indicators) as Defects Per Million
Opportunities, Inventory Months of Supply, Claims percentage for freight costs, On-time pickups,
Transit time, On Time Line Count, Customer Order Promised Cycle Time, providing a flexible way to
improve supply chain unit performance.
Once you have developed your Supply Chain metrics, the next logical question
is...Is my result good or bad? Benchmarking allows you to compare your results to
other companies.
One of the keys to successful benchmarking is to rate your company against like
companies.
Backorder: An unfilled customer order. A backorder is demand (immediate or past
due) against an item whose current stock level is insufficient to satisfy demand.
This calculation can vary. Some companies count items that are not confirmed (not
allocated) and past the Requested Delivery Date (or Requested Ship Date). Other
companies may also count those items with stock confirmed, but past due
Other considerations:
1. Partials - what if a customer orders 100 pieces of an item. You currently have 90 pieces.
Should the 100 pieces be considered a backorder or should the backorder be considered 10
pieces (100 ordered - 90 available)? The answer is it depends. If the customer accepts a
shipment of a partial quantity, then the 90 pieces will ship out and the backorder is 10 pieces.
If the customer only accepts only full quantities, then the backorder is 100 pieces. This is
because, in the customers eyes, they ordered 100, but you did not ship them anything.
2. Multi Line Orders - what is a customer places an order for 3 different items and they
request you hold the order until you can ship it completely. You have inventory to fill the first
two items, but not the third. Are all 3 items then on backorder? While there is no specific
standard, generally you would only consider the third item as on backorder.
Here are just a few of the many Cycle Times you should consider for your Supply
Chain. All of these measures should not only calculate the days (or hours) from the
start and finish, but also between the various steps in between.
Customer Order Promised Cycle Time: The anticipated or agreed upon cycle time
of a Purchase Order. It is gap between the Purchase Order Creation Date and the
Requested Delivery Date.
This tells you the cycle time that you should expect (NOT the actual)
Customer Order Actual Cycle Time:
The average time it takes to actually fill a customers purchase order. This measure
can be viewed on an Order or an Order Line level.
The measure starts when the customers order is sent/received/entered. It is
measured along its various steps of the order cycle. Through credit checks, pricing,
warehouse picking and shipping. The measure ends at either the time of shipment
or at the time of delivery to the customer (sometimes tracked by using an EDI
#214). This "actual" cycle time should be compared to the "promised" cycle time.
Manufacturing Cycle Time:
Measured from the Firm Planned Order until the final production is reported. It
usually takes into account the original planned production quantity versus the
actual production quantity. Example: X% of the planned quantity must be
completed on a production run or the cycle time should not be considered.
Purchase Order Cycle Time:
Measured from the creation of the PO to the receipt at your location (Distribution
Center, Hub etc). One of the keys here is not not have your RDD (Requested
Delivery Date) exceed the agreed to lead time. If it does, it may artificially inflate
your Lead Time.
Additionally, any in-between points available will add value to the metric.
Example: Creation of the PO, Shipment from the Vendor, Receipt at the DC. This
will tell you the manufacturing time vs the transit time.
Inventory Replenishment Cycle Time:
Measure of the Manufacturing Cycle Time plus the time included to deploy the
product to the appropriate distribution center.
Cash to Cash Cycle Time:
The number of days between paying for Raw Materials and getting paid for
product. Calculated by Inventory Days of Supply plus Days of Sales Outstanding
remaining 3 items on March 10. The Fill Rate for this Purchase Order is 70%. It is
calculated once the initial shipment takes place.
Calculation: Number of Order Lines Shipped on the Initial Order* / Total Number
of Order Lines Ordered (7/10 = 70%)
SKU Fill Rate: The number of SKU's (Stock Keeping Units) ordered and shipped
is taken into consideration. Above, we consider each Order Line to have an equal
value (1 ). Here, we count the SKU's per Order Line.
example: If on Line 1, the order was for 30 skus of product "AB" and on line 2,
they ordered 10 skus of item "AC". If Line 1 ships on April 1 and line 2 on April
20, the the SKU Fill Rate is 75%
Calculation: Number of SKUs Shipped on the Initial Shipment / Total Number of
SKUs Ordered (30/40 = 75%).
Case Fill Rate: The amount of cases shipped on the initial shipment versus the
amount of cases ordered.
example- ABC Company orders 6 products that total 200 cases. The manufacturer
ships out 140 cases on 3/1/01 and the remaining 60 cases on 3/10/01. The Fill Rate
for this Purchase Order is 70%. It is calculated once the initial shipment takes
place. The number of Order Lines is not considered in this calculation. This Fill
Rate measure gives "weight" to the order lines that are shipped out.
Calculation: Number of Cases Shipped on the Initial Order / Total Number of
Cases Ordered . (140/200 = 70%)
Value Fill Rate: Same as above, except the order line value is used instead of cases.
Calculation: Value of Order Lines Shipped on the Initial Order / Total Value of the
Order ($400/$500 = 80%)
What happens if a customer orders 10 products, but then decides to expedite out
just one of them? Should the other 9 products be counted as a Fill Rate "miss"? ( 1
shipped / 10 ordered = 10%). The answer is no. You should factor rushed lines out
of your Fill Rate calculation. This can usually be done by identifying the routing
code (as in an SAP system) or by the carrier (FEDX).
*NOTE: "Shipped on the Initial Order" - usually refers to the first shipment out of
the primary warehouse. Therefore, if an order line ships out of an alternate
shipping facility and it ships out on/before the first shipment out of the primary
warehouse, then it is considered a + to the Fill Rate.
Here's one quick method for determining your ABC ranking based on Annual Sales
Volume:
1. Calculate the 12 month dollar usage for all of your products (volume X cost).
2. Rank the items in descending order by the dollar usage.
3. The "A" items are the top 80% of the total annual usage dollars.
4. The "B" items make up the next 15% of total annual usage.
5 The "C" items are the remaining items are the remaining 5% with >0 usage in the
past 12 months
6. Label zero-usage items can be labeled as "D".
You will also need to make a special consideration for your newer products. If you
don't have a full year of Sales Volume to reference, you need to use a yearly
forecast estimate instead.
There are also other considerations, such as "critical items" that may have low
usage, but need special monitoring because you can't run out of stock due to a
customer agreement. So your definition of A items may need to be customized.
Some companies use A, B, C, CA = 80%, B = 15%, C = 4%, C- = 1%
GMROI (Gross Margin Return on Inventory)
GMROI = (Unit Selling Price of an Item - Unit Inventory Value of an Item) X
Annual Demand for the item
Average Inventory Value of the product.
Notes:
Unit Inventory Value tells you what it costs you to make the product.
The Unit Selling Price - Unit Inventory Value tells you the margin.
-----------------------------------------------------------------------------------------------------------------------------------------Inventory Carrying Rate:
This can best be explained by the example below....
1. Add up your annual Inventory Costs:
Example:
$800k = Storage
$400k = Handling
$600k = Obsolescence
$800k = Damage
$600k = Administrative
$200k = Loss (pilferage etc)
$3,400k Total
2. Divide the Inventory Costs by the Average Inventory Value:
Example:
$3,400k / $34,000k = 10%
3. Add up your:
9% = Opportunity Cost of Capital (the return you could reasonably expect if you
used the money elsewhere)
4% = Insurance
6% = Taxes
19%
4. Add your percentages: 10% + 19% = 29%
Your Inventory Carrying Rate = 29%
--------------------------------------------------------------------------------------------------------------------------------Inventory Carrying Costs:
Inventory Carrying Cost = Inventory Carrying Rate (see above) X Average
Inventory Value
Example: $9,860,000 = 29% X $34,000,000
Inventory Turns (Inventory Turnover): The number of times that a companies
inventory cycles or turns over per year. It is one of the most commonly used
Supply Chain Metrics.
Calculation: A frequently used method is to divide the Annual Cost of Sales by the
Average Inventory Level.
Example: Cost of Sales = $36,000,000. Average Inventory = $6,000,000.
$36,000,000 / $6,000,000 = 6 Inventory Turns
OR
Inventory Turns can be a moving number.
Example: Rolling 12 Month Cost of Sales = $16,000,000. Current Inventory =
$4,000,000
$16,000,000 / $4,000,000 = 4 Inventory Turns
Projected Inventory Turns: Divide the "Total Cost of 12 Month Sales Plan" by the
"Total Cost of Goal Inventory"
Example: The Total Cost of 12 Month Sales Plan is $40,000,000. Total Cost of
Goal Inventory = $8,000,000
$40,000,000 / $8,000,000 = 5 Projected Turns
Turns can be viewed using Cost Value, Retail Value, or even in Units. Just make
sure that you're using the same Unit of Measure in both the Numerator and the
Denominator.
Although results vary by industry, typical manufacturing companies may have 6
inventory turns per year. High volume/low margin companies (like grocery stores)
may have 12 inventory turns per year or more.
Consult a qualified benchmarking company to help you set your target for your
inventory turns.
Please see the category links on the left side to view various Supply Chain
definitions.
On Time Performance
example- ABC Company orders 10 products (one order line each) on its Purchase
Order #1234. The Order has a Requested Ship Date of March 1. The manufacturer
ships out 5 line items on February 28 and 2 items on March 1 and the remaining 3
items on March 10. The OnTime LineCount for this Purchase Order is 70%. It is
calculated based on the Requested Ship Date OR, if available, substitute actual
Delivery Date vs Requested Delivery Date.
Calculation: Number of Order Lines Shipped on or before the Requested Date /
Total Number of Order Lines Ordered
(7/10 = 70%)
OnTime SKU Count: The number of SKU's (Stock Keeping Units) ordered and
shipped is taken into consideration. Above, we consider each Order Line to have an
equal value (1 ). Here, we count the SKU's per Order Line.
example: If on Line 1, the order was for 30 skus of product "AB" and on line 2,
they ordered 10 skus of item "AC". The Requested Ship Date is April 1st. If Line 1
ships on March 28 and line 2 on April 20, the the SKU Fill Rate is 75%
Calculation: Number of SKUs Shipped OnTime / Total Number of SKUs Ordered
(30/40 = 75%).
OnTime Case Count: The amount of cases shipped OnTime versus the amount of
cases ordered.
example- ABC Company orders 6 products that total 200 cases, on its Purchase
Order #1235. The manufacturer ships out 140 cases on 3/1/01 and the remaining 60
cases on 3/10/01. The Requested Ship Date is 3/1. The Case OnTime Rate for this
Purchase Order is 70%. The number of Order Lines is not considered in this
calculation. This OnTime measure gives "weight" to the order lines that are
shipped out.
Calculation: Number of Cases Shipped OnTime / Total Number of Cases Ordered .
(140/200 = 70%)
OnTime Value Rate: Same as above, except the order line value is used instead of
cases.
Calculation: Value of Order Lines Shipped OnTime / Total Value of the Order
($400/$500 = 80%)
Perfect Order Measurement: As with most other Supply Chain Metrics, there are
many variations to this measurement.
The Perfect Order Measure calculates the error-free rate of each stage of a
Purchase Order. This measure should capture every step in the life of an order. It
Transportation Metrics:
Freight cost per unit shipped: Calculated by dividing total freight costs by number
of units shipped per period. Useful in businesses where units of measure are
standard (e.g., pounds). Can also be calculated by mode (barge, rail,ocean,
truckload, less-than-truckload, small package, air freight, intermodal, etc.).
Outbound freight costs as percentage of net sales: Calculated by dividing outbound
freight costs by net sales. Most accounting systems can separate "freight in" and
"freight out." Percentage can vary with sales mix, but is an excellent indicator of
the transportation financial performance.
Inbound freight costs as percentage of purchases. Calculated by dividing inbound
freight costs by purchase dollars. It is important to understand the underlying
detail. The measurement can vary widely, depending on whether raw materials are
purchased on a delivered, prepaid, or collect basis.
Transit time: Measured by the number of days (or hours) from the time a shipment
leaves your facility to the time it arrives at the customer's location. Often measured
against a standard transit time quoted by the carrier for each traffic lane. Unless
you are integrated into your customers' systems, you will have to rely on freight
carriers to report their own performance. This is often an important component of
leadtime. Transit times can vary substantially, based on freight mode and carrier
systems.
Claims as % of freight costs: Calculated by dividing total loss and damage claims
by total freight costs. Generally measured in total and for each carrier. A high
number generally indicates packaging problems, or process problems at the carrier.
Freight bill accuracy. Calculated by dividing the number of error-free freight bills
by the total number of freight bills in the period. Errors can include incorrect
pricing, incorrect weights, incomplete information,etc. Generally measured in total
and for each carrier.
Accessorials as percent of total freight: Calculated by dividing accessorial and
surcharges by total freight expenditures for the period. Many freight carriers will
charge extra fees for trailer detention/demurrage, re-delivery, fuel increases, and
other expenses or extra services. Often, these are extra costs incurred due to
inefficient processes.
Percent of truckload capacity utilized : Generally used for shipments over 10,000
lbs. Calculated by dividing the total pounds shipped by the theoretical maximum.
For example, assume your trucks can hold 40,000 lbs. of product. During the prior
month, there were 675 shipments totaling 22.95MM lbs. The percentage utilization
was 85%. The 15% unused capacity is an opportunity for more efficiency.
Mode selection vs. optimal: This is calculated by dividing the number of shipments
sent via the optimal mode by the total number of shipments for the period. To
measure this, each traffic lane must have a designated optimal mode, based on
freight costs and customer service requirements.
Truck turnaround time: This is calculated by measuring the average time elapsed
between a truck's arrival at your facility and its departure. This is an indicator of
the efficiency of your lot and dock door space, receiving processes, and shipping
processes. This also directly affects freight carrier profits on your business.
Shipment visibility/traceability percent : Calculated by dividing the total number of
shipments via carriers with order tracking systems, by the total number of
shipments sent during a period. This is an indicator of the relative sophistication of
your carrier base, and one measure of the non-price value available from your
carrier base.
Number of carriers per mode: Calculated by counting the total number of freight
carriers used in a given period, by mode (ocean, barge, rail, intermodal, truckload,
LTL, small package, etc.). This is an indication of your volume leverage and
control over the transportation function.
On-time pickups: Calculated by dividing the number of pick-ups made on-time (by
the freight carrier) by the total number of shipments in a period. This is an
indication of freight carrier performance, and carriers' affect on your shipping
operations and customer service.
Various Supply Chain Metrics:
Benchmarking: One way to set your goals is Benchmarking. There are various
benchmarking services, that for a fee, will compare your company to other "like" companies.
You submit your answers to a set of questions. Those answers are averaged in with other
companies submissions. Averages are calculated and World Class levels are set.
As an example, if the average Fill Rate for your industry is 93% and your performing at a
80% level, then it's obvious you need to set an aggressive goal. However, if the industry
average is 93% and you're at 94%, you may want to target a minimal gain. Your aggressive
efforts should probably be focused in other areas. The caveat here is defining "like"
industries. Make sure the comparison your making is a fair one.
SMART goals :
Specific: Provide enough detail so that there is no question on what is being measured and no
question how the metric is calculated. You should be specific as to the measurement, goals
and responsible people/department.
Measurable: Here is where you use your metric. Make sure you have a reliable system in
place that will accurately measure your performance
Attainable: Will the Supply Chain projects you have scheduled for the year produce results
that will achieve your goal? The person setting the goal and the person responsible for
achieving the goal should agree with the target. If results are un-attainable or unrealistic, they
will have a de-motivating effect on your employees.
Realistic: Don't plan to do things if you are unlikely to follow through. Better to plan only a
few things and be successful rather than many things and be unsuccessful. Your Supply Chain
goals should be challenging, but realistic in relation to the improvement projects you have in
place.
Time frame: Identify when your targeting to hit your goal.
Example: Your current Fill Rate is 87% and your Supply Chain projects should improve your
measure to 93%. But is the 93% goal for the final month of the year OR is it averaged out
over a specific timeframe?
Customer Service Policy:
Additionally, make sure that your Supply Chain goals are aligned with your Customer
Service Policy.
Example: Your agreement to your customer might be a 95% Fill Rate, with an Order Cycle
Time of 10 days. Make sure that your goals reflect these customer agreements.
Supply Chain optimization is difficult to achieve. But with the right metrics in place and
proper goals set, you now know where to focus your improvement projects. You have just
gotten closer to Supply Chain optimization