SCM Notes
SCM Notes
UNIT – I INTRODUCTION 9
Supply Chain – Fundamentals –Evolution- Role in Economy - Importance -
Decision Phases - Supplier- Manufacturer-Customer chain. Supply chain strategy
- Enablers/ Drivers of Supply Chain Performance. Overview of Supply Chain
Models and Modeling Systems.
Total: 45
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TEXT BOOKS
1. Janat Shah, Supply Chain Management – Text and Cases, Pearson
Education, 2009.
2. Sunil Chopra and Peter Meindl, Supply Chain Management-Strategy Planning
and Operation, PHI Learning / Pearson Education, 2007.
3. David Simchi-Levi, Philip Kaminsky, Edith Simchi-Levi, Designing and
Managing the Supply Chain: Concepts, Strategies, and Cases, Tata McGraw-
Hill, 2005.
REFERENCES
1. Altekar Rahul V, Supply Chain Management-Concept and Cases, PHI, 2005.
2. Shapiro Jeremy F, Modeling the Supply Chain, Thomson Learning, Second
Reprint , 2002.
3. Ballou Ronald H, Business Logistics and Supply Chain Management, Pearson
Education, Second Indian Reprint, 2004.
4. Joel D. Wisner, G. Keong Leong, Keah-Choon Tan, Principles of Supply Chain
Management- A Balanced Approach, South-Western, Cengage Learning 2008.
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UNIT – I
INTRODUCTION
Eg.
Unilever Big Bazaar Customer wants
detergent and goes
to a retailer
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A supply chain is dynamic and involves the constant flow of information, products and
funds between different stages.
A typical supply chain may involve a variety of stages. These supply chain stages include
o Customers
o Retailers
o Wholesalers/Distributors
o Manufacturers
o Suppliers (Component or Raw Material)
Upstream Downstream
Objective of Supply Chain:
The value a supply chain generates is the difference between what the final product is
worth to the customer and the costs the supply chain incurs in filling the customer’s
request.
Supply chain profitability or Surplus:
It is the difference between the revenue generated from the customer and the overall cost
across the supply chain.The higher the supply chain profitability, the more successful is
the supply chain.
Effectiveness of Supply Chain:
A supply chain is effective when the flow of products, information and funds is managed
effectively and efficiently.
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o Supply chain management (SCM) is the term used to describe the
management of the flow of materials, information, and funds across the entire
supply chain, from suppliers to component producers to final assemblers to
distribution (warehouses and retailers), and ultimately to the consumer.
o These organizations have their own objectives and these are often conflicting.
o Therefore, there is a need for a mechanism through which these different
functions can be integrated together.
o Therefore coordination between the various players in the chain is key in its
effective management.
Objective is to be able to have the right products in the right quantities (at the right place)
at the right moment at minimal cost.
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Benefits of Supply Chain:
o Lower costs
o Improved quality
o Higher profit margins
o Creation of better facilities for manufacturing, product design research.
o Better customer service
o Efficient manufacturing
o Better trust among the partners leading to win-win
Design Decisions:
o Chain Configuration
o Resources Allocation
o Process Design for each stage
o Forecast of demand
o Which Market will be supplied from which location
o Subcontracting of manufacturing
o Inventory policies
o Timing and size of marketing
o Price promotions
3. Supply Chain Operation – The time horizon here is weekly or daily, and
during this phase companies make decisions regarding individual customer
orders. Goal is to handle incoming customer orders in the best possible
manner.
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Customer
Customer
Order Cycle Pull
Retailer
Replenishment
Cycle
Distributor
Manufacturing
Cycle
Manufacturer Push
Procurement
Cycle
Supplier
o Setting a date that an order is to be filled
o Generating pick lists at a warehouse
o Allocation of order to a particular shipping mode and shipment
o Setting delivery schedules of trucks
o Placement of replenishment orders
Given the constraints established by the configuration and the planning policies,
the goal during the operation phase is to exploit the reduction of uncertainty and
optimize performance.
Process Views of a Supply Chain:
A supply chain is a sequence of processes and flows that take place within and between
different stages and combine to fill a customer need for a product. There are two different
ways to view the processes performed in a supply chain.
Each cycle occurs at the interface between two successive stages of the supply chain.
o Within each cycle, the goal of the buyer is to ensure product availability and to
achieve economies of scale in ordering.
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o The supplier attempts to forecast customer orders and reduce the cost of receiving
the order.
o The supplier then works to fill the order on time and improve efficiency and
accuracy of the order fulfillment process.
o The buyer then works to reduce the cost of the receiving process.
o Reverse flows are managed to reduce cost and meet environmental objectives.
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Each cycle consists of six sub-processes.
Push/Pull View: The processes are divided into two categories depending on whether
they are executed in response to a customer order or in anticipation of customer orders.
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PUSH/PULL BOUNDARY
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Thus, a push/pull view of the supply chain is very useful when considering strategic
decisions relating to a supply chain design.
The goal is to identify an appropriate push/pull boundary such that the supply chain can
match supply and demand effectively.
Supply chain macro processes in a firm:
Within a firm, all supply chain activities belong to one of the three macro processes given
below. The three macro processes manage the flow of information, product and funds
required to generate, receive and fulfill a customer request.
1. Customer Relationship Management
2. Internal Supply Chain Management
3. Supplier Relationship Management
Integration among the three macro processes is crucial for successful supply chain
management.
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Wal-Mart’s Competitive Strategy – High availability of a variety of products of
reasonable quality at low prices.
The given below are few of the functional strategies that form part of the competitive
strategy of a company:
The value chain emphasizes the close relationship between the functional
strategies within a company.
Each function is crucial if a company is to satisfy customer needs profitably.
The various functional strategies cannot be formulated in isolation.
They are closely intertwined and must fit and support each other if a company is
to succeed.
Strategic Fit: It means that both the competitive and supply chain strategies have aligned
goals.
It refers to consistency between the customer priorities that the competitive strategy
hopes to satisfy and the supply chain capabilities that the supply chain strategy aims to
build.
Understanding Customers
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o The desired rate of innovation in the product
Uncertainty from the customer and the supply chain can be combined and mapped on the
implied uncertainty spectrum.
Like customer needs, supply chains have many different characteristics that
influence their responsiveness and efficiency
Supply Chain Responsiveness: It includes the supply chain’s ability to do the following:
Respond to wide range of quantities demanded
Meet short term lead times
Handle a large variety of products
Build highly innovative products
Meet a high service level
Handle supply uncertainty
The more of these abilities a supply chain has, the more responsive it is.
Supply Chain Efficiency: It is the inverse of the cost of making and delivering a product
to the customer. Increase in cost lowers efficiency.
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Responsiveness
High
Low
High Low
Cost
For a given level of high responsiveness, the cost can not go beyond the lowest point as
shown in the above graph.
Step 3: Achieving Strategic Fit: This step aims to match supply chain responsiveness
with the implied uncertainty from demand and supply. The supply chain design and all
functional strategies within the firm must also support the supply chain’s level of
responsiveness.
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Finding the zone of strategic fit:
Responsive
Supply Chain
Zone
Responsiveness of
Spectrum Strategic
Fit
Efficient Supply
Chain
Competitive Strategy
Finance Strategy
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UNIT II
LOGISTICS MANAGEMENT
Logistics:
The process of moving and positioning inventory to meet customer requirements at the
lowest possible cost.
Logistics Management:
The managerial responsibility to design and administer a system to control the flow and
positioning of material, work-in-process, and finished inventory to support business
strategy
Logistics Structure:
Warehousing:
WAREHOUSING
A warehouse is a commercial building for storage of goods. Warehouses are used by
manufacturers, importers, exporters, wholesalers, transport businesses, customs, etc.
They are usually large plain buildings in industrial areas of cities and towns. They usually
have loading docks to load and unload goods from trucks. Sometimes warehouses load
and unload goods directly from railways, airports, or seaports. They often have cranes
and forklifts for moving goods, which are usually placed on ISO standard pallets loaded
into pallet racks.
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Types of Warehouses
The warehouse is the most common type of storage though other forms do exist (e.g.,
storage tanks, computer server farms). Some warehouses are massive structures that
simultaneously support the unloading of numerous in-bound trucks and railroad cars
containing suppliers’ products while at the same time loading multiple trucks for
shipment to customers.
Processes and IT
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Receiving
Put away
Order preparation / picking
Shipping
Inventory management (cycle counting, addressing...)
Co-packing
Kitting
Repair
A piece pick, also known as broken case pick, split-case pick, each pick, over-pack or
pick/pack, is a type of order selection process where product is picked and handled in
individual units and placed in an outer carton, tote or other container before shipping.
Catalog companies and internet retailers are examples of predominantly piece-pick
operations. Their customers rarely order in pallet or case quantities; instead, they
typically order just one or two pieces of one or two items.
Warehouse management systems often utilize Auto ID Data Capture (AIDC) technology,
such as barcode scanners, mobile computers, wireless LANs and potentially Radio-
frequency identification (RFID) to efficiently monitor the flow of products. Once data
has been collected, there is either a batch synchronization with, or a real-time wireless
transmission to a central database. The database can then provide useful reports about the
status of goods in the warehouse.
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Warehouse management systems can be stand alone systems, or modules of an ERP
system or supply chain execution suite.
The primary purpose of a WMS is to control the movement and storage of materials
within a warehouse – you might even describe it as the legs at the end-of-the line which
automates the store, traffic and shipping management.
In its simplest form, the WMS can data track products during the production process and
act as an interpreter and message buffer between existing ERP and WMS systems.
Warehouse Management is not just managing within the boundaries of a warehouse
today, it is much wider and goes beyond the physical boundaries. Inventory
management,inventory planning, cost management, IT applications & communication
technology to be used are all related to warehouse management. The container storage,
loading and unloading are also covered by warehouse management today.Warehouse
management today is part of SCM and demand management. Even production
management is to a great extent dependent on warehouse management. Efficient
warehouse management gives a cutting edge to a retail chain distribution company.
Warehouse management does not just start with receipt of material but it actually starts
with actual initial planning when container design is made for a product. Warehouse
design and process design within the warehouse (e.g. Wave Picking) is also part of
warehouse management. Warehouse management is part of Logistics and SCM.
Warehouse management deals with receipt, storage and movement of goods, normally
finished goods, to intermediate storage locations or to final customer. In the multi-
echelon model for distribution, there are levels of warehouses, starting with the Central
Warehouse(s), regional warehouses services by the central warehouses and retail
warehouses at the third level services by the regional warehouses and so on. The
objective of warehousing management is to help in optimal cost of timely order
fulfillment by managing the resources economically. Warehouse management =
"Management of storage of products and services rendered on the products within the
four walls of a warehouse"
Transportation
Transport involves
– equipment (trucks, planes, trains, boats, pipeline),
– people (drivers, loaders & un-loaders), and
– decisions (routing, timing, quantities, equipment size, transport mode).
When deciding the transport mode for a given product there are several things to
consider:
• Mode price
• Transit time and variability (reliability)
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• Potential for loss or damage.
Transport Cost:
– Fixed costs:
• Terminal facilities
• Transport equipment
• Carrier administration
• Roadway acquisition and maintenance [Infrastructure (road, rail,
pipeline, navigation, etc.)]
– Variable costs:
• Fuel
• Labor
• Equipment maintenance
• Handling, pickup & delivery, taxes
Transportation Objectives:
1. To move product from an origin location to a prescribed destination
2. Minimize costs (Temporal, Financial and Environmental) and expenses (Loss or
damage )
3. Meet the customer demands regarding delivery performance and shipment
information availability
Transportation functionality:
Provides two major functions
– Product Movement :
• Primary function of moving products up and down the value chain
• Involves movement of materials, components, work-in-progress or finished
goods between phases of production and to the ultimate consumer
– Product storage
• Transportation vehicles offers expensive, temporary storage of the product
• It is justified
– From the total cost or performance perspective when loading and unloading
costs are high,
– In case of capacity constraints
– By its the ability to extend lead times
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Participants in Transportation Decisions
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• It consists of the rights-of-way, vehicles and carrier organizations that offer
transportation services for hire or internal basis
• The nature of infrastructure determines the economic and legal
characteristics of the modes of transport
Modes of Transport:
• Rail
– Low cost, high-volume [Products: Heavy industry, minerals, chemicals,
agricultural products, autos, etc.]
– Improving flexibility
– intermodal service
• Water
– One of oldest means of transport
– Low-cost, high-volume, slow
– Bulky, heavy and/or large items (Products: Nonperishable bulk cargo -
Liquids, minerals, grain, petroleum, lumber, etc )]
– Standardized shipping containers improve service
– Combined with trucking & rail for complete systems
– International trade
• Motor
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– Most used mode
– Flexible, small loads [Products: Medium and light manufacturing, food,
clothing, all retail goods]
– Trucks can go door-to-door as opposed to planes and trains.
• Air
–Rapidly growing segment of transportation industry
–Lightweight, small items [Products: Perishable and time sensitive goods:
Flowers, produce, electronics, mail, emergency shipments, documents,
etc.]
– Quick, reliable, expensive
– Often combined with trucking operations
• Pipeline
– Primarily for oil & refined oil products
– Slurry lines carry coal or kaolin
– High capital investment
– Low operating costs
– Can cross difficult terrain
– Highly reliable; Low product losses
Suppliers
Containerships
Coordinated air
and truck
UNIT III
NETWORK DESIGN
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