Lean, Outsourcing and Kaizen in Retail: March 2018
Lean, Outsourcing and Kaizen in Retail: March 2018
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Radojko Lukić
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Radojko Lukic
2
Preface
E-mail: [email protected]
3
About the Author
E-mail: [email protected]
4
Part 1. The effe cts of application of lean concept in retail
Abstract
Introduction
6
Table 1.The influence of lean thinking on the transformation of the
retail business.
8
The benefits of lean retailing
9
This figure illustrates that retailers and producers themselves gain
benefits from the lean retail. Application of lean fundamentally changes
the relationship between retailer and supplier. By using the concept of
lean retail, global retailer Wal-Mart has established a "new relationship"
with suppliers, which allows him to realize significant bene fits arising
from econo mies of scale and size. This gives him the basis fo r the
unique retail business model na med "daily price reductions".
The effective imple mentation of lean approach in retail makes grea ter
cost efficiency, increased worker productivity and less waste of time
and effort. This in return significantly affects the improvement of
customer satisfaction and store profitability.
10
For example, the study found that there is a similar corporate
philosophy of business between T oyota and Seven-Eleven Japan (SEJ).
Both companie s achieve very good business pe rformance, create a
unique corporate philosophy and operate globally around the world.
Table 2 gives diffe rent viewpoints of manu fa cturing and retailing
towards the concept of lean management.
Lean management
Manufa cturing Retailing
TPS (Toyota General mode l Seven-Eleven key concept
production and concept
syste m)
1 JT (Ju st in Time) SCM (Supply CDC (Combination distribution
chain center), NDF (Non-deliverable
manage ment) forward)
2 Kanban syste m DCM (Demand Store initiative ordering
chain
manage ment)
3 Production SCM (Supply Team merchandising
smoothing chain
manage ment)
4 Shortened setup SCM (Supply Customer focus
time chain
manage ment)
5 Shortened lead Order-delivery Dominant strategy
time
6 Standardization of Franchise syste m Store initiative ordering
operations
7 Autonomy In store Individual store management
me rchandising
8 Kaizen In store team Tanpinkanri (ite m by ite m
(Improvement me eting control)
activities)
Source:Naruo,(2007)
11
Application of lean system is particularly pronounced in clothing
retailers. Figure 2 illustrates the concept of lean in clothing retail and
relationship with the supplier.
Frequent special
store delivery
This figure shows that, according to the concept of lean, retail store
needs more spec ial supplies - continuous replenish ment of retailer's
placed orders which are based on information relating the sale collected
in real-time by bar code scanning on the retailer' s cash register. Data on
sale s of individual items are aggregated centrally and used for placing
orders to suppliers, usually on a weekly basis. Based on lean approach
and supported by information and communication technology effects of
inventory manage ment re sult in in-store inventory reduction and
increased profita bility. By applying the concept of lean, retail develops
special relations with suppliers which allow the flow of goods and
information to be optimized.
12
3. Efficient consumer re sponse
The concept of efficient consu mer response (ECR) introduces not only
the optimization of logistics. Data collection via scanners and cash
registers provide information about the buyer' s behavior (who are the
buyers, what, when and where they buy?), which can be used as a base
to create marketing strategy for n ew product develop ment for the ta rget
group of customers. Retailers and manufacturers are able therefore to
effectively adapt to customers' de mand range. Retailers can also
successfully use collected data fo r the systematic development of new
products with manufacture rs or, in the case of private labels, with their
own particular group of retailers.
All in all, electronic data interchange (EDI) and quick response (QR)
improve relations between retailers and suppliers, a llowing retail prices
to be reduced by 10% (Berman, 2010).
13
4. Managing product categories
16
6. Lean consumption
So, for example, by applying the lean thinking company IKEA has less
human e ffort, less capital investment, shorter time, several factorie s and
stocks are at an a cceptable (target) level. All this has positive e ffect on
its business performance.
Distribution technologies
- Conveyors/sortation systems
- Automated storage & retrival
- Cross-docking
- 3PL
- Pick and pack
- Voice-directed picking
Lean supply means mapping (determining) the flow and eliminating all
types of losses in the supply chain. Research in practice determined that
the application of lean / just-in-time (JIT) practices significa ntly
contributes to reducing the execution time of received orders.
18
There are some differences betwe en lean and agile approaches. In some
cases the lean approach does not allow for e fficient management of
internal processe s or external relations. It is better in conditions of high
and predictable demand, with some supplies, so tha t functional products
can be created. In the case of low volume, high sensitivity of the supply
chain, unpredictable customer's requirements and difficult control of
suppliers' capacity and innovation, quick response or agile approach
based on product innovation is preferable (Cox, 2005). Table 5 shows
the profiles of lean and agile product (i.e. supply chain).
19
Conclusion
Reference
21
Manage ment ma tters in retail, Institute for Competitiveness &
Prosperity, Working Paper 13, April 2010.
Piercy, N.F. and Morgan, N.A. (1997), "The Impact of Lean Thinking
and the Lean Enterprise on Marketing: Threat or Synergy?", Journal of
Marketing Management, 13, 679-693.
22
Stratton, R. and Warburton, R.D.H. (2003), "The strategic integration of
agile and lean supply", International Journal of Production Economics,
85, 183-198.
23
Part 2. The influence of outsourcing of perfor mance in retail
Abstract
24
Introduction
In the retail sec tor, under the c onditions of stro ng competition and
limited purchasing power of buyers / consumers opportunities to
increase profits through price control (i.e. increase) are limited.
Opportunities to increase profits by reducing the total costs (as the su m
of costs of goods sold and operating expenses), particularly operating
costs are significantly greater. In order to reduce costs in retail, modern
strategic cost management techniques are being simultaneously applied.
As part of that, the importance of outsourcing is increasing, and it is
reflected in more profitable choice o f purcha sing instead of own
production - procure ment of goods and services from independent
external suppliers. Outsourcing is, in its essence, a contractual
relationship between external supplier and company (as purchaser), by
which he takes responsibility for the efficient execution of one or more
of its business functions. It is considered, both in theory and in practice,
that outsourcing is a significant potential source of revenue for retailers
who apply this strategic technique in different busin ess areas, in fina nce
and administration, human resources management, in procurement and
information tech nology. The effects result in significant reduction of
total costs (according to resea rch in practice up to 30%) and,
consequently, increased profits in retail (according to Retail: Outsource
' til You Drop, Outsourcing Yearbook 2011).
25
Two typical types o f outsourcing services are: technology and business
process. Technology outsourcing service includes electronic commerce
(e-comme rce), infrastructure (network), software (applications),
telecommunications, Web site development and their maintenance.
Business process outsourcing service s include buyer's contact
information (customer relationship manage ment), equipment, fina nce
and accounting, human resources, logistics, supply chain manageme nt,
procurement and security.
The term outsourcing is not new - it has a long history. In 19th century
Britain imported cotton from the United States, spun cotton is weaved in
fa ctories in England, and the finished product is then exported abroad,
mainly in India as its colony (Niranjan, 2011). The concept of
outsourcing became especially popular in 1962 when Ross Perot formed
a company c alled Electronic Data System (EDS). Today EDS is multi-
billion dollar company, with over 70,000 employees and it is one of the
major global BOP (business process outsourcing) firms (Agarwal, 2007).
27
Today, outsourcing is, generally speaking, very important strategic
management tec hnique. There are clear indications based on the
available e mpirical data, especially for developed countries. The global
trend of outsourcing is a s follows: in 2009 growth rate was 4%; average
annual growth rate since 2005 is 9.7% and the market value of over $
580 billion. Market share of individual categories is the following:
information technology outsourcing (Information Technology
Outsourcing - ITO) 50%, the business proce ss outsourcing (Business
Process Outsourcing - BPO) 43% and electronic data processing
(electronic data processing - EDP) 7% (Quoted from: www.zylun.com /
outsourcing-global statistics).
By its nature, the logistics business is re sponsible for the efficient and
effective handling of firm' s goods in accordance with the defined
objective of minimizing costs, improving custo mer service and creating
competitive advantage (Bourlakis, 2011). Logistics outsourcing process,
in the literature also known as contract logistics and third party logistics
(3PL), has considerable relevance. Third party logistics are defined as
external companies that perform logistics functions, instead of
traditional within the organization. Functions that are performed by
third party logistics may include the entire logistics process or selection
of activities within it.
Advantages Disadvantages
Reduction in capital Loss of control
investment in facilities,
information technology
and manpower
Firm beco mes more Lack of appropriate informa tion
flexible to adapt to technology syste ms linking the
changes and respond various fir ms in the chain
quicker to demands
3PL firms convert a fixed Failure to select or manage 3PL firms
cost to a variable costs appropriately
Inventory turnover ratio Unreliable promise given by 3PL
is improved fir ms, inability to respond to
changing requirements and lack of
understanding of user' s business
goals
31
It could be more cost- Apprehension in user's e mploy ees
efficient co mpared with about job security
in-house operations
Improving customer Difficulty in assessing any benefits
service and satisfaction and cost savings gained through
outsourcing
Acquiring outside
expertise
There are many reasons, as noted above, for the use of outsourcing in
the retail trade (Figure 1).
33
Table 3. Main empirical reasons to use outsourcing
34
INDIVIDUAL - Loss of in-house expertise
- Severance or transfer costs of existing IS staff
36
INPUT and OUTPUT
Sales Sales and
prospect sales growth
Marketing Logistics Customer
conversion
support ratio
Source:Tarikere(2011)
37
High 138.81 144.72 133.29 134.74 146
outsourcers
(Score
range - 11
to 16)
Note: The data from 260 online retailers helped divide the companies
into three categories. In this statistical analysis, the lower the number,
the better the performance.
As seen from the data presented in a given table, the best performance is
in the mid-level outsourcing. This in itself suggests that every retailer
should look at the optimal ratio between the width of outsourcing and
internal operations. The net effect is imp roving the business and
financial performance.
The research conducted on the example of the company Zara repo rted
the merits and deme rits o f using outsourcing services. They are detailed
in Table 5.
Advantages Disadvantages
Focusing on the co mpany's No knowledge of its own retail
core competitiveness
Better return on investment For the purposes of developing
qualitative relationships more
time on communication is needed
38
Better cost control It is not ea sy to communicate
with the special partners
More focus on R & D High costs of integrating data
(research and development)
Improve performance by Product knowledge will be
timely presence on the market disclosed by the suppliers
No need for investment on It is not easy to build trust with
purchasing new ma chines for suppliers
making new products
Reducing the total cost
Improved product quality and
reliability
Flexible retail service
Less risk of releasing new
products on the market
Improving custome r service
(quick respond for sampling
and mass production)
Less investment and faster
execution of orders P
Conclusion
Reference
41
Kosowska, E. (2008), IT outsourcing market in Poland, PMR
Publications (www.intandtelecompland.com).
Niranjan, T.T. and Rao, S.S. (May/June 2011), "A Toolkit for Balanced
outsourcing", Industrial Manage ment, pp. 19-24.
42
Rigby, D. and Bilodeau, B. (2011), Management Tools & Trends, Bain &
Company.
43
Part 3. The effe cts of application kaizen concept in food retail
Abstract
All retail sectors, including food sector, apply numerous strategies and
techniques of modern business as a function of improving ma rket,
business, financial and sustainability performance. One of the m is the
application of the concept of kaizen - the Japanese business
philosophy. The essence of the concept of kaizen is small, but
syste matic "continuous improve ment" of process in order to increase
productivity, improve quality of products / servic es, reduce re spo nse
time (customer service), reduce costs (goods and business), eliminate
waste and maximize value creation (through the retail chain), especia lly
for customers. Conducted research on the application of kaizen concept
in food retail, particularly in the West, showed significant improvements
in productivity, food sa fety, relationships with cu stomers, reduction of
cost and wa ste, all of which has a positive impact on the achievement of
better market, business, financial and sustainability performa nce.
Concerning those positive experiences, all retail food chains, especially
in developing and transition countries should also apply the concept of
kaizen in order to achieve target profit perfo rmance, with maximum
satisfaction of customers needs. In addition to highlighting the
importance of empirical significance, this paper points out the specific
supportive concepts, innovative methods of conducting business - kaizen
methodology in food retail.
44
Introduction
For all the retailers that apply the concept of kaizen, special
significance has just-in-time operations syste m tool, as well as
supporting concepts of continuous improve ment: collaborative planning,
45
forecasting and inventory replacement, quick response delivery system,
electronic data interchange, coding, electronic commerce, multi -
channel retail, private label development, and customer (and suppliers)
relationship mana gement (Levy, 2007; Lukic, 2011).
There are signific ant diffe rence s between Japanese and Weste rn
approaches to continuous improve ment, i.e. kaizen and innovation.
Kaizen continuous improve ment is oriented on people and existing
technology (without significant investment). As a way of continuous
improvement innovation (product or process) is based on significant
investments in new technology. Kaizen is a gradual long-term
continuous improvement. Innovation is a significant short-te rm
continuous improve ment. In retail sale s a number of innovative business
models are implemented (regardless of the type of business - food or
non-food goods) in order to achieve a target profit with maximizing
customer satisfaction (Sorescu et al., 2011).
Starting fro m the general theoretical ideas about the concept of kaizen,
this paper mainly analyzes the problems and effects of applying kaizen
in the food retail. These findings should serve as a message to apply the
concept of kaizen in all retail food chains, espe cially in developing
countries and transition economies, such as Serbia and its neighboring
countries.
46
1.Proble ms, aims and methods of analysis of the effects o f Kaizen
concept application in food retail.
In retail sales today there are numerous strategies and techniques for
improving the business market, business and financial performance
(Berman, 2010; Lukic, 2012 a, b and c). This includes the application of
the concept of kaizen - the Japanese business philosophy, small
syste matic continuous improvement of process in order to increase
productivity, improve quality, shorten time, reduce costs, eliminate
waste and maximize value creation, particularly for custo mers. Specific
proble ms o f application of kaizen concept in food retail were caused by
the very nature o f the businesses. In addition to the practical analysis of
the results they are also the subject of thorough analysis in this paper.
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2. The diffe rences between retail kaizen and lean methodology
To achieve the objectives of retail kaizen (in all sectors, including food)
the cycle "plan - do - check - action" is very important. At each stage in
the cycle plan - do - check - action retail kaizen is implemented through
the development, implementation and evaluation. Initial phases of a
given cycle in (food) retail are: 1) evaluation of data, 2) establish of
kaizen team, 3) map existing process, 4) map the ideal process, 5)
analysis of the ca use s, and 6) the development of counter-measures. The
focus is on increasing custo mer satisfaction. In connection with the
question: What do customers want (?), three important principles are: no
defects, timeliness and caring. In addition, creating a better retail
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experience has a positive effect on profitability in all retail sectors.
Table 1 presents the general application of Toyota's key learning
methods in retail, which is, with certain adjustments, applicable to all
sectors, including food.
Plan Check
50
Do Action
51
4. Kaizen costing and budget in food retail
Target costing and kaizen costing are two comple mentary methods for
continuous costs reduction and value increase (in all retail sectors).
Regardless, there are significant differences between the m. Ta rget
costing (in food retail) focuses on the redesign o f products or se rvices
as a function of cost reduction. The first stage in calculating the target
cost is use of co ntinuous improvement (kaiz en) and operational control
in order to reduce costs. Kaizen is a small continuous process
improvement, fast and efficient performance of existing activities
without their elimination. Target costing is based on the realization of
the custome r' s wants and needs, while kaizen costing focuses on the
accomplish ment of manager's pro fit goals. Both methods, because of the
significant cost reduction, decrease selling prices over time, which has a
positive impact on attracting customers and, thereby, increasing the
profitability.
The calculation of target costs and kaizen costing (in food retail) largely
rely on the activity-based costing (Rof, 2011). Activity-based costing
provides a basis for understanding the benefits and costs of each activity
in the food retail value chain (Lukic, 2013).
According to the Kaizen Institute, the company Sonae has the best
practice of continuous improvement as a means of stimulating
innovation and generating competitiveness. It includes all employees in
the continuous improve ment process, and the key objectives are to
create value, customer satisfaction and eliminate waste. Kaizen project
has changed the way the company' s stores are operating, significantly
increased efficiency and productivity and, in addition, has changed the
culture of conduct of all employees a s well a s their relationship with
customers. Now, Sonae is a company where the innovation is priority for
all e mployees, and where every employee tries to do its work " fa ster and
more efficiently".
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"By applying kaizen management in Serbia considerable success would
be achieved in the development o f the domestic economy" - said founder
of kaizen practices and Director of Kaizen In stitute Masaaki Imai during
one visit. In time s of transition kaizen is, in his opinion, the ideal way
to overcome difficult period with minimal investment and relianc e on
human resources. The consequences of the global econo mic crisis may
be diminished, according to him, by direct application of kaizen in all
areas of busine ss (including retailers, especially food).
One of the leading processors of coffee, Strauss Adriatic was a mong the
first in Serbia to imple ment this philosophy in order to improve their
own business. Implementation of kaizen in this co mpany began in 2010
when the first training started. Application of specific principles began
after a visit to Japan Tobacco International in Romania 2011. In
accordance with the basic principles of kaizen "that all aspects of the
business should be continuous, with the optimum use of all available
resource s and with an e mpha sis on the development of hu man qualities,"
responsible mana gers developed a plan for the implementation of this
philosophy in the co mpany Strauss Adriatic.
Conclusion
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References
59
Lukic, R. (2013), Accounting of trade enterprices, Faculty of
Economic s, Belgrade (Raþunovodstvo trgovinskih preduzeüa, Ekonomski
fakultet, Beograd).
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