Final Exam Flashcards
Process for integrating marketing and operations plan to develop a tactical plan
Sales and Operations Planning (S&OP)
S&OP attempts to balance ____ and ____
Supply and demand
S&OP balancing objectives Finance (3):
- High ROI
- Maximize return
- Minimize risk
S&OP balancing objectives Marketing/Sales (3):
- Many product variations
- Fast response, high service
- Maximize revenue
Balancing objectives Operations (4):
- Fewer products
- Long, stable production runs
- Maximize output, minimize cost
- Reduce variance, maintain ‘up-time’
Quantitative benefits of S&OP (4):
- Improved forecast accuracy
- Higher customer service
- More stable supply
- Better new product information
Qualitative benefits of S&OP (4):
- Better organizational teamwork
- Faster and better aligned decision making
- Better business visibility
Operations planning costs: People costs (6):
- Regular Production
- Overtime
- Hiring
- Fire/Layoff
- Weekend (1.5x or 2x on Sundays)
- Holidays (2x or 3x)
Operations Planning Costs: Material Costs (3):
Also must consider:
- Holding inventory
- Shortage
- Subcontracting
Must also consider require resource investment
S&OP Strategies (3):
- Level
- Hybrid
- Chase
Produce at the same rate every period
Level
Produce any combination of level or chase
Hybrid
Produce exactly what is needed each period
Chase
Most common S&OP strategy
Hybrid
S&OP strategy ideal for supply chain
Level
S&OP strategy ideal for marketing
Chase
Multiple Objectives to what S&OP strategy is best (4):
- Costs
- Employee considerations
- Customer expectations
- Difficulty or ease of adjusting capacity
The ability to product, hold, receive, store, or accommodate
Capacity
An approach for determining the overall capacity level of capital intensive resources, including facilities, equipment, and size of overall labor force
Capacity planning
Capacity ratings (3):
- Design capacity
- Available capacity
- Actual capacity
Design capacity is capacity that you ___ and should be ____
Paid for
Achievable
Available capacity is ____ capacity minus ____
Design
Lost units
Quality issues: scrap and rework
Actual capacity is ____ capacity minus _____
Available
Inefficiencies
Ex. Breakdowns, late starts/Early quits, shortages of input materials
Proportion of design capacity being used
Capacity utilization
Capacity utilization % = [___/___] x ___
[Actual output/Design capacity] x 100
Accounts for issues with design capacity
Efficiency Percentage
Efficiency % = [____/____] x ____
[Actual output/Actual capacity] x 100
Determining capacity requirements (3):
- Forecast sales for each individual product or service
- Calculate equipment and labor requirements to meet the forecasts
- Develop and Evaluate capacity alternatives (internal and external)
Capacity alternatives: Internal sources (4):
Investment and Risk low to high:
- Efficiency
- Flexibility
- Expansion/Addition
- New facilities
Capacity alternatives: External sources (5):
Investment and Risk low to high:
- Outsourcing
- Subcontracting
- Sharing capacity
- Joint ventures
- Acquisitions
Computer-based information system that schedules and orders dependent-demand inventory components (internally focused)
Material Requirements Planning (MRP)
Material Requirements Planning (MRP) uses 3 primary inputs:
- Master Production Schedule (MPS)
- Bill of Materials (BOM)
- Inventory records
Material Requirements Planning (MRP) outputs recommendations (2):
- When to release new orders
- When to reschedule open orders
Expansion of MRP that also considers labor, MRO, equipment, etc. in addition to materials (internally focused to organization)
Manufacturing Resource Planning (MRP II)
Expansion of MRP/MRP II that also considers all of the external/outside factors from needed suppliers outside of the organization in addition to internal needs or inputs from other departments
Enterprise Resource Planning (ERP)
Demand for an item is independent of the demand for other items. These demands are typically determined by outside customers
Independent demands
Demand for a component is dependent on the demand for the end-item into which the component goes
Dependent Demand
Independent demand involves ____
Forecasting
Dependent demand involves ____
MRP, MRP II and ERP
Logistics is _____, _____, and _____, the efficient, effective flow and storage of __________ from point of origin to point of consumption
Planning, implementing, and controlling
Goods, services, and related information
Logistics includes ___ and ___ flows
Forward and reverse
Logistics are typically focused ____ firms but flow ____ firms is also logistics
Between
Within
Inbound logistics =
External upstream (suppliers)
Material flow =
Internal firm or company (OEM facility or network)
Outbound logistics =
External downstream (Customers)
Logistics military roots (2):
Conquest through _____
- Alexander the Great
- Romans
Conquest through better logistics
Logistics transportation (2):
- Steam power (Ships and Railroads) (1800s)
- Internal combustion engines (Trucks and Planes) (1900s)
Logistics communication (2):
- Electrical (mid 1800s)
- Digital (1990s)
Logistics is ___ to the _____
Key
Global economy
Logistics accounts for approximately ___% of the US GDP
10%
Over $___ per year spent on logistics
$1 trillion
Logistics accounts for approximately ____ jobs and ___% of the total labor force
15 million jobs
14%
Logistics can be ___ of economic ____
Basis
Activity
Some industries could obtain productivity improvements of ___-___% by focusing on logistics
20-35%
Top global logistics hubs for freight (seaport) (5):
- Shanghai
- Singapore
- Tianjin
- Guangzhou
- Qingdao
Top global logistics hubs for freight (airports) (5):
- Hong Kong
- Memphis
- Shanghai
- Anchorage
- Incheon
Logistics costs:
Motor carriers __%
Other carriers __%
Motor carriers 49%
Other carriers 13%
Logistics costs:
Warehousing __%
Inventory carrying cost __%
Other costs __%
Warehousing 11%
Inventory carrying cost 22%
Other costs 4%
Logistics cost total = $___
$1095 billion
The 7 “Rights” of Logistics (In perfect order)
Right..
- Product
- Customer
- Time
- Place
- Condition
- Quantity
- Cost
Logistics value add (3):
- Availability
- Final transformation
- Costs
Availability value (3):
Time, place, quantity
Final transformation value (2):
Packing/Presentation and postponement
Costs value (3):
Production costs, distribution costs, reduced risks
Logistics value = [____/____]
Quality or Utility / Cost or Price
Current logistics challenges:
- Outsourcing
- Just-in-time (JIT)
- Security
- Transportation infrastructure
- Fuel price volatility
- Pressure on margins
- Globalization
- Talent management
- Sustainable practices
Current outsourcing challenge =
Logistics growth
All the activities from the time of a sales inquiry until the order is delivered to the customer
Order fulfillment
Order fulfillment includes ____, ____, and _____ with all associated information flows
Processing, preparing, and shipping customer orders
Items are available when and where desired by the customer
Product Availability
Items are unavailable when and where desired by the customer
Stockouts
Typical stockout frequencies:
Brick and mortar retailers:
Non-advertised items ___%
Advertised items ___%
Online retailers __%
Non-advertised items 7-10%
Advertised items 16%
Online retailers <5%
% of ordered items delivered
Item fill rate
% of order lines filled in total
Line fill rate
Orders shipped complete
Order fill rate
Customer Expectations (5):
- Speed
- Consistency
- Flexibility
- Transparency
- Recovery
Speed = ____
Order-to-delivery (OTD)
Consistency = (2)
On-time delivery, promised lead times are met
Flexibility =
Agility (react to short-term changes)
Transparency = (3)
- Real-time information
- No surprises
- Bad news does not improve with age
Recovery = (2)
- Contingency planning
- Improve customer satisfaction?
Contingency planning lifecycle (6):
Disruption planning-> Risk Assessment-> Recovery plan-> Enact/Execute-> Evaluate-> Improve
The time between recognition of need until the product is delivered and ready for use
Order Cycle
Stocked Product =
Make-to-stock (MTS)
Make-to-stock similar processes exist for (3):
- Assemble-to-order (ATO)
- Make-to-order (MTO)
- Engineer-to-order (ETO)
Handle orders (Steps 1-3)
\_\_\_ = fast and accurate \_\_\_ = no errors \_\_\_ = available to deliver, available to promise
Inquiries
Order entry
Promise date
Available to Deliver (ATD) =
Available to Promise (ATP) =
In stock
Reliably on the way
Partial fill =
Drop-ship =
Partially in-stock
Direct from factory
One large shipment made of many smaller shipments
Consolidation
Consolidation can happen by (3):
- Market Area (Combine small shipments from one shipper going to the same area)
- Pooled delivery (Combine small shipments from different shippers going to the same area)
- Schedule delivery (delivery at specific times)
Shipping Plan (Steps 5-7)
- ___ = where is it going, who will move it
- ___ = what route to follow, transportation management system (TMS)
- ___ = Size/weight of order, delivery timing
- Build loads
- Route
- Choose carrier
Gather items (Steps 8-12)
- ____ = (if from external source)
9.
10.
- ____ = shipping documents - shipper, packing list, manifest
12.
- Receive product
- Pick order
- Pack order
- Load order
- Ship order
Delivery at customer (Steps 13-15)
- ____ = customer checks for perfect order, match shipper with receipt
- ____ = If needed
- ____ = Customer matches this, receipt, and PO - mistakes/delays are costly
- Customer receipt
- Install/prep
- Invoice
Why is fulfillment important? (3 part triangle)
Top to bottom:
- Customer success (Assist customers in meeting objectives)
- Customer satisfaction (meet or exceed customer expectations)
- Basic service (product availability, lead time performance, service reliability)
Its more than just technology/system. But technology is useful in data gathering about customers to develop strategic relationships (often captured in this software such as: salesforce, oracle CRM, MS dynamics)
Customer Relationship Management (CRM)
Revenue low, profit low
Review reason for doing business
Revenue high, profit low
High basic service or customer satisfaction
Revenue high, profit high
Commitment to customer success
Revenue low, profit high
High basic service or customer satisfaction
Commitment to customer success typical percentage of # of customers:
20-30%
5 major modes of transportation:
- Air
- Truck
- Pipeline
- Rail
- Water
The durable physical assets required to facilitate transportation
Transportation infrastructure
Truck (Motor carrier) carries ___% of US domestic freight
70%
Truck normal US load limits ____ pounds
80,000
Truck infrastructure paid for by ____ and shared with ____
Governments
Public
LTL =
TL =
Less-than-truckload
Truckload
LTL is too big to be handled ___, too small to ____
___ to ___ pounds
Manually
Fill a truck
150 to 10,000 pounds
Truck carriers:
Terminals used to ____
Line-haul is from ____
Smaller trucks transport between _____
Consolidate loads
Terminal-to-terminal
Shippers and terminals
Examples of LTL carriers:
- Fedex freight
- XPO logistics
- YRC freight
- Old Dominion Freight line
- UPS freight
Shipments move directly from the shipper location to the consignee location
Truckload (TL or FTL)
Truckloads focus on _____ (usually ____ lbs
Full trailers
Greater than 10,000 lbs
Truckload rates are less than LTL rates because (4):
- Shipper loads goods and consignee unloads goods
- One stop
- No terminals
- Administrative costs for 25,000lb shipment about the same as for 250lb shipment
Truckload US carriers (3):
- Swift
- Schneider
- J.B. Hunt
Trucks cost:
Trucks speed:
Trucks reliability:
Trucks capability:
Trucks capacity:
Trucks flexibility:
Cost - moderate-to-high
Speed - fast
Reliability - weather, congestion
Capability - 80,000 lbs per truck (michigan is 164,000 lbs total)
Capacity - Available for hire
Flexibility - Very flexible
____ is generally the fastest mode for shipments exceeding ___ miles
Air
600
Air carrier
____ services adds cost and time
_____ used for rates
“Accessorial”
“Dimensional weight”
Air carriers best suited for ____, ____, ____, _____, or ____ deliveries; examples:
High-value, lower-volume, urgent, perishable, or time-specific deliveries
Examples: electronics, cut flowers, spare parts
Air carriers is used for ____ of US domestic freight
Less than 1%
Air carriers:
Cost =
Speed =
Reliability =
Capability =
Capacity =
Flexibility =
Cost = expensive
Speed = Fastest
Reliability = Weather; congestion; intermingling with passengers
Capability = tight weight and size restrictions
Capacity = limited
Flexibility = Runways > 10k ft
Pipeline carrier is only mode without ______ and is ____ transportation
vehicles/vehicle operators
One-way
Pipeline tends to be the ____
Slowest mode
Pipeline products must be ___, ____, or ____
Liquid, liquefiable, or gaseous
Pipeline is capable of transporting _______ but has high ______, but very low ______ due to large product volume
Large product volumes
Fixed costs
Cost per unit
Pipeline carriers:
Cost =
Speed =
Reliability =
Capability =
Capacity =
Flexibility =
Hugh investment but cheap to operate
Slowest speed
Extremely reliable
Liquids and gasses
Large
Very limited
Rail carrier is wide _____ and large ____
Variety of cargo
Capacities
Rail capacity is ___ per railcar and up to ____ per train
100+ tons per railcar
15,000 tons per train
Rail carriers (4):
- CSX
- Norfolk Southern
- Burlington Northern
- Union Pacific
Rail carriers dominated by ____ carriers, domination limits ___ and ___ options
Four
Service and pricing
Rail carriers:
Cost =
Speed =
Reliability =
Capability =
Capacity =
Flexibility =
Moderate cost
Moderate speed
Congestion
Few restrictions
Large
Rail access
Water carriers move about ___% of global trade and has a ____ of cargo
80%
Wide variety
Water carriers:
Cost =
Speed =
Reliability =
Capability =
Capacity =
Flexibility =
Cheap cost
Slow speed
Arrival time variance
Very few restrictions
Hugh capacity
Water access
Mode summary:
Best mode for:
Cost: Speed: Reliability: Capability: Capacity: Flexibility:
Cost - Pipeline Speed - Air Reliability - Pipeline Capability - Water Capacity - Water Flexibility - Truck
Mode summary:
Worst mode for:
Cost: Speed: Reliability: Capability: Capacity: Flexibility:
Cost: Air Speed: Pipeline Reliability: -- Capability: Pipeline Capacity: Air Flexibility: Pipeline
Using a container or other equipment that can be transferred from the vehicle of one mode to the vehicle of another mode without the contents being reloaded or disturbed
Intermodal transportation
Intermodal transportation is usually interchangeable among ___, ___, and ___ carriers and provides significant reduction in ____ costs
Rail, truck, and water
Freight handling
Intermodal containers are large reusable ____ boxes used for intermodal shipments
Steel
Prior to intermodal containers: $___/ton to load a ship
With containers: $___/ton to load a ship
$6.00/ton
$0.15/ton
One TEU (twenty-foot equivalent) =
8’ x 8’ x 20’ long
Parcels are packages weighing up to ___ pounds
150
Offer service to shippers to consolidate small shipments into bulk shipments for better rates
Freight forwarders
Freight forwarders splits shipment at ___ and can arrange ____
Destination
Local delivery
Freight forwarders companies:
- DHL
- DB Schenker
- Kuehne + Nagel
- Sinotrans
Shipper’s associations are similar to air and freight forwarders but are ____ organizations and primarily focus on achieving the ____ for members
Not-for-profit
Lowest rates
Provide transportation to clients and often operate their own equipment
Third party logistics companies (3PLs)
Third party logistic companies examples:
FedEx 3PL, UPS 3PL, CH Robinson
Common carriers are legally obligated to offer _____ at nondiscriminatory prices to the general public
Transportation service
Contract carriers offer ____ service to customers on a ____ basis
No obligation to service the ____ or to treat customers on an ___ basis
Specialized service
Contractual
General public
Equal
Companies whose primary business is other than transpiration and provide their own transportation services (ex. Wal-Mart)
Private carriers
Commercial terms established by the ______
International Chamber of Commerce (ICC)
ICC defines the __, __, __, and __ associated with the transportation and delivery of goods from seller to buyer
Tasks, obligations, costs, and risks
ICC is widely used in ____ and ____ and is generally accepted _____
International logistics and procurement
Worldwide
Delivery is the point in the transaction where the _____ to the goods is transferred from the seller to the buyer
Risk of loss or damage
The point named in the incoterm to which carriage has been paid
Arrival
Seller has an obligation to deliver the goods to a named place for transfer to a carrier
Free
To file shipper’s export declaration and get export permit
To clear for export
Storing products at or between point of origin and point of consumption
Warehousing
Bringing together similar stocks from different sources, consolidating
Accumulating (bulk making)
Breaking larger quantities into smaller quantities
Allocating (bulk breaking)
Building up a variety of different products for resale to particular customers
Assorting
Receiving product and shipping it out the same day or overnight without putting it into storage
Cross-docking facility
Warehouse design considerations:
___ over ___
____ and ____ to be handled
____
Function over form
Quantity and character of goods to be handled
Purpose
Efficient and effective warehousing management can be an ___ task - requires constant ____
Exacting
Diligence
Packaging 3 general functions:
- Promote
- Protect
- Identify (label) the contents
Packing decisions involve a number of departments within an organization:
Engineering, manufacturing, marketing, warehousing, transportation, quality
Regulations govern labeling (3):
- Weight
- Specific contents
- Instructions for use
The short-distance movement that usually takes place within a building such as a plant or DC and the load/unload to a transportation service provider
Material handling
Material handling
Value =
Quality or Utility / Price or cost
Consolidation of several units into larger units to improve efficiency in handling and to reduce shipping costs
Unit loads
Most common unit load platforms (2)
Pallets and skids
Network design:
Design implies ____ vs. organic/evolutionary growth over time
Intentional action
Intentional network design (3):
- Customer
- Look for patterns and clusters
- Balance economics of supply, manufacturing, storage, and transportation
Cost per unit of weight decreases as shipment size increases
Economy of scale
Cost per unit traveled decreases as distance moved increases
Economy of distance
Network dimensions (4):
- Vertical integration
- Flexibility
- Cooperation
- Geographical dispersion
Facility location factors (4)
- Cost
- Customer service expectations
- Accessibility
- Availability
A network design used when a consistent set of cities are targeted for delivery
Hub and spoke
Integrated logistics is management of _______ as a _____, instead of separate management of _____ functions
Entire logistics chain
Single entity
Individual logistics
Shift cost from one logistics function to another to achieve better total system cost
Cost-to-Cost trade-offs
Increased service levels -> increased costs
Cost-to-service trade-offs
Ex. Zappos overnight shipping
Sum of all product and logistics related costs
Total landed costs
Planning, evaluating, implementing, and improving sourcing decisions, both routine and strategic, for all goods and services
Procurement
Purchased goods and services account for ___-to___% of every dollar of revenue
50%-90%
Direct labor costs typically account for only about __% of the sales dollar
10%
Categories of goods (3):
Direct
Indirect
Strategic
Raw materials, parts, pieces, components
Direct goods
Maintenance, repair, and operating supplies
Indirect goods
Facilities and major machinery and equipment
Strategic Investment goods
Procurement is usually the ___ authorized agent
Sole
Buyer has no firm commitment/timeline for spending, determine supplier capabilities and interest
Request for information (RFI)
Suppliers suggest solutions with corresponding quotes, often use with complex specs, permits supplier input/creativity/innovation, increases difficulty of evaluation
Request for Proposal (RFP)
Suppliers quote to specs, Almost always used for simple specs, but can be used for complex specs if no deviations allowed
Request for Quote (RFQ)
Using one supply source for a justifiable reason
Single or Sole-source
Multiple sources (usually 3-12 suppliers) bid on RFQs or RFPs
Competitive bidding
Multiple suppliers (often >10) are invited to bid on a single RFQ
Reverse auction
Supplier trade off between ____ and _____
Competition and complexity
Evaluate potential suppliers (3):
- Financial health
- Track record
- Ethics
Two steps to evaluating quotes/bids:
- Develop criteria (before bids are received)
2. Compare and analyze
Quotes/Bids criteria (5):
- Price
- Quality
- Delivery
- Capability
- Risk
Quote/Bid total cost (3):
Acquisition cost
Ownership cost
Post-ownership cost
Quote/Bid quality (4)
- Conformance
- Performance
- Durability
- Warranty
Quote/Bid delivery (2):
Timing
Mode