The Role of Optimization in World Class CPG Supply Chains: Takeaway for Indian FMCG. 27 th February 2009
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1 The Role of Optimization in World Class CPG Supply Chains: Takeaway for Indian FMCG 27 th February 2009
2 Proposed Agenda Brief JDA Introduction Supply Chain Process Evolution & Significance: Indian Context Change Theory (3-C Model) Value Matrix Analysis & Manufacturing Relevance Indian FMCG Manufacturers: Business Challenges Broad Spectrum FMCG Sectorial Perspective Avenues of Supply Chain Process Re-engineering Optimization Opportunities: Solution Roadmap Process Overview Integrated Solution Approach International Case Learning Discussion Q & A
3 JDA We are defined by our customers : Over 1,400 retailers worldwide market leader Over 3,500 supplier customers 22% compound annual growth in customer base JDA Retail Customers JDA Supplier Customers since Q00 4Q00 2Q01 4Q01 2Q02 4Q02 2Q03 4Q03 2Q04 4Q04 2Q05 4Q Q00 3Q00 4Q00 1Q01 2Q01 3Q01 4Q01 1Q02 2Q02 3Q02 4Q02 1Q03 2Q03 3Q03 4Q03 1Q04 2Q04 3Q04 4Q04 1Q05 Retail Top 50 Market Share Retail Top 100 Market Share Retail Top 500 Market Share JDA JDA JDA Broad representation Non-JDA in large Non-JDA and mid-sized Non-JDA retailers 61% 44% 60%
4 Global Presence Global Presence United States Canada Japan Singapore Dubai Malaysia Australia Mexico Chile Brazil United Kingdom Netherlands Norway France Spain Italy China India Americas EMEA Asia Pacific Our global presence ensures a JDA service/installation office is always within reach
5 Leading Companies Across the World Endorse the JDA Supply Chain Solution as the Platinum Standard Manufacturing & Wholesale-Distribution Over 3,650+ Manufacturers More than 500+ Wholesale-Distributors 83 of the Top 100 Global Consumer Goods Manufacturers 28 of the Top 50 Life Sciences Manufacturers 4 of the Top 5 five Oil & Chemical Manufacturers 2 of the Top 3 Telecom Manufacturers Retail Over 1,400+ Retailers 71 of the Top 100 Retailers 17 of the Top 19 Fortune 100 Retailers 13 of the Top 20 Global Retailers 9 of the Top 10 Hardlines and Softlines Retailers 9 of the Top 10 Grocery Retailers 8 of the Top 10 North American Retailers Over 5,550 Customers Worldwide 65% of Sales From Repeat Customers
6 Some of our CPG Customers Worldwide
7 Some Indian Customers who Chose JDA Solutions
8 JDA in Asia 13 years in Asia Offices Singapore, Sydney, Melbourne, Tokyo, Shanghai, India 270 Customers 488 product installations Over 500 JDA associates Offices in Hyderabad, Bangalore and Mumbai
9 The Beginning Setting SCM Strategic Objectives Interenterprise Coordination of Manufacturing and Business process Effective Distribution and Channel Partnerships Customer Responsiveness and Accountability
10 Optimization is the Key Retailer Supplier Supplier Manufacturer Manufacturer Manufacturer DC DC Retailer Retailer Retailer C o n s u m e r s Subcontractor ERP Approach
11 SCM Approach: End to End Optimization Emerging World Class Model Retailer Supplier Supplier Manufacturer Manufacturer Manufacturer DC DC Retailer Retailer Retailer C o n s u m e r s Subcontractor Information Sharing for Coordinated Management
12 Synchronized Supply Chain Freight Audit & Payment Manufacturers Demand Planning Suppliers Transportation Visibility Dynamic S&OP Scorecards Transportation Network-Wide Market Basket Planning Performance Analysis Management Retailers CPFR/VMI Trade Promotions Management Forecasting Promotions Inventory Network Design Planning Management Lifecycle Pricing SYNCHRONIZATION Exception Monitoring Consumer Suppliers Multi-echelon Transportation Exception MonitoringInventory Planning Optimization Replenishment & Allocation Manufacturing Carrier Capacity Planning & Planning Scheduling Order Promising Price & Promotions Advanced POS Network Planning Planning Design & Markdown Optimization Optimization Predictive Analytics Master Planning Distribution Planning
13 Creates One Synchronized View of Demand across Supply Chain, Sales and Marketing Tyson Foods is the world s largest processor and marketer of chicken, beef and pork, the second-largest food production company in the Fortune 500 and a member of the S&P 500 Improved forecast accuracy from 10 to 15 percent, each percentage represents approximately 2-3 million pound of inventory Generates statistical forecasts, track promotional events, and measure forecast performance with individual business units Collaborates demand forecasts with sales and marketing, allows for review and approval processes among stakeholders to achieve consensus demand plans
14 Boosts new product offerings and customer service levels CCBCC supports 11 states in US with a total of 54 distribution centers spread across these states. Sales to other bottlers has shown growth of over 30 % annually. Annual sales of over $1.4 billion. Number of items quadrupled in the past 4 years JDA s products provided clear financial and operating results A lot of people talk about collaboration but we re actually doing it and we certainly would not be as successful without the help of JDA Software. - Brett Frankenberg, director of supply chain planning, CCBCC Quantifiable Benefits Successful launch of 300 percent new product offerings 50 percent reduction in inventory levels 15 percent increase in customer service levels Won Sam s Club Supplier (Soft Drink) of the Year in 2006 Improved view of financial and operating results
15 Integrated supply chain for all North American businesses Complexity within the supply chain has increased o Higher number of new product introductions, and especially date-sensitive products o Growth trends in many categories resulting in capacity constraints o Higher co-packer usage has reduced direct control over production and therefore requires a greater need for strategic planning and coordination o Greater than ever challenges to deliver products that meet Integrated supply chain for meat customers and bakery shelf divisions life requirements in North America while including maintaining raw material low planning, manufacturing, inventory, inventory distribution, obsolescence and fleet management as well as periodic network/flow-path planning Established a solid S&OP process based on solid and unified view of the supply chain Achieved corporate goal to meet minimum level of inventory obsolescence incorporated datesensitive inventory management into daily supply chain planning Improved consensus planning and execution across sales, marketing, supply chain, manufacturing, and logistics
16 Fast ROI is essential for the competitive Asian markets Heinz ABC Indonesia is one of the biggest manufacturers in food business in Indonesia. Their major business-lines are Soya Sauce, Canned Fish, Syrup and Ready-To-Drink. It took only 13 weeks for Heinz ABC to implement the collaborative forecast solution Generates statistical forecasts which provides a baseline for strategic sales and marketing developments Successful results have inspired and motivated the solution to be rolled-out in other South East Asia countries
17 Leading Australian agribusiness Significant cost savings and inventory reductions with D&F in agribusiness Business Challenges The client s inventory turnover had decreased by 50%, with some stock-out issues arising due to poor forecast accuracy, forecast bias and safety stock issues Sales market experiences significant seasonality creating challenges for effective supply chain planning and management The distribution network was suboptimal due to acquisitions, mergers and local organic growth over time The complete end-to-end supply chain planning and S&OP processes were analyzed and redesigned The solution delivered $20M in annual cost savings and a $50M inventory reduction with achievement of full annual savings in two years
18 JDA Case Learning Circuit City implemented our Lifecycle Pricing solution - Improved revenue - Improved unit sales - Improved gross margin Staples leveraged CPFR/VMI solution Reduced Product Returns by 3% Lower Inventory by 10% Improved Forecast Accuracy by 26% 2004 Manugistics, Inc. Company Confidential
19 JDA Case Learning Canadian Tire Implemented Forecasting and Replenishment Reduced inventory by $70 million -Improved inbound service levels by 20% -Decreased order lead time from 46 days to 15 days Publix implemented forecasting and replenishment Decreased Out of Stocks (OOS) Decreased Inventory levels at warehouses and stores Increased Sales 2004 Manugistics, Inc. Company Confidential
20 JDA Case Learning HEB implemented Collaborative Planning -- Improved customer service Reduced inventory costs Improved product availability JC Penney implemented Forecasting & Replenishment and Promotions Planning Improved effectiveness of promotions -Increased forecast accuracy -Reduced stock outs and excess inventory 2004 Manugistics, Inc. Company Confidential
21 PWC Report for IBEF
22 Operational Constraints: Live with this Order-specific delivery requirements, such as appointments, loading rules, routing rules, carrier preferences, consolidations. Equipment requirements. Product compatibility rules. Service requirements for customers, suppliers, plants, and warehouses. Customer specific shipping and delivery time windows. Location Constraints (Throughput Capacity) Traffic conditions/transit Delays
23 Visibility and Performance Management: Where to go now
24 JDA Offers for Indian FMCG What is in it for ME from JDA
25 Optimization Framework AOP Validation Generate Flexible Demand Number (SnOP) Optimize Long Lead Contracts and Network Simulate Top and Bottom Line with many Scenarios Quarterly Validation Generate Optimized Monthly plans Generate Scenario of Variance Monthly and Operational Validation Generate Highly Optimized Schedules of Production Generate Highly Optimized Schedules of Logistics
26 Demand Management Demand Components Demand Decomposition Demand Classification Seasonal Profiling Business Objectives More stable and accurate forecasts Increased stability for inventory management Reduces need for statistical expertise & maintenance Key Capabilities Classify and analyze history Calculate statistical models Measure forecast performance Understand impact of promotions to baseline sales Differentiate between seasonal and promotional lift in sales history Time-phased statistical forecasting methods Promotional planning & analysis
27 Replenishment & Allocation Components Fulfillment Distribution, Deployment, CPP, BTL, DSI, Supersession, SKU Substitution Dynamic Demand Response Order Optimization Allocation Business Objectives Integrate distribution planning, order optimization, allocations, and VMI Create optimized orders and time-phased inventory plans Drive lower inventories and fewer expedited shipments by producing a more accurate daily demand picture Allocate finite product based on prioritized metrics Key Capabilities Time-phased distribution & inventory planning Optimal order execution and management Deployment of constrained supply Date-sensitive inventory management Dynamic deployment for inventory re-balancing Managing product transitions Consider the desired ordering schedule, constraints, calendars, safety stock and logistical restrictions to determine the Suggested Order Quantity Leverage different distribution flow methods based on item and vendor characteristics
28 Supply & Manufacturing Master Planning Supply Sequencing Components Business Objectives Generate a time-phased, daily feasible supply and manufacturing plan Generate a detail manufacturing schedule that respects material, capacity, and service Provide forward visibility to manufacturing and procurement Increase speed and quality of decision-making process Key Capabilities Demand Prioritization, Priority-Based Supply Selection Multi-Site/Stage Production Simultaneous Material & Capacity Constraints Scorecard, Plan Analysis, Exceptions, Order Pegging Production Grouping to Minimize Changeover Complex Bill-of-Material Attribute-based Scheduling Deep Tree Algorithm, Genetic Algorithm
29 Network & Inventory Optimization Strategy Components Inventory Policy Optimization Business Objectives A decision-support solution to evaluate the tradeoff between costs and constraints for Site selection Capacity plan Sourcing plan Contingency plan Develop long-range material, capacity, and sourcing plans Optimize inventory targets across the supply chain Set optimal mix of service level across items Key Capabilities Flexible supply chain modeling Simultaneous costs and constraints optimization Incorporate capacity, lead time, demand variability, lead time variability, fiscal budget & service target Cost metrics, geographic map, and plan analysis Deterministic & stochastic optimization
30 The Opportunities: JDA Value Propositions How can JDA help? 3-5% customer service improvement 5-15% global inventory reduction 15-20% global reduction in production and logistics costs 30-45% increased supply chain planning productivity with significantly less manual analysis or intervention The strategic benefits to your business Increased revenue and market share Reduced working capital Reduced operating costs Improved market responsiveness Low IT cost Low risk and scalable implementation
31 Discussions
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