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In today’s economy we see many companies emphasizing “cash flow management” over profitability.  That is, they are willing to sacrifice some profit dollars in order to invest smaller amounts in inventory.  If you find yourself in this situation, I have an alternative reordering strategy that may meet this need for many of you.

When placing a replenishment order, how do your buyers decide how much of each item to order?  Often, reorder quantities are based on “habit” (i.e., “this is the way we’ve always done it”) rather than logic.  However, most computer systems will allow you to reorder using an economic order quantity (EOQ).  This is the quantity that will minimize the total cost of inventory for each piece of each product with recurring usage that you buy.  The EOQ balances four factors:

·         The current forecast demand for the product

·         The cost of carrying inventory (also known as the “K” cost)

·         The cost of issuing a replenishment order (also known as the “R” cost)

·         The replacement or landed cost per piece of the item

It is important that these four factors of the EOQ are accurate.  In previous newsletters we’ve discussed forecast accuracy.    You can also find articles on the subject on our web site, www.EffectiveInventory.com.  We also provide free help in calculating your “K” and “R” costs in the articles “The Mysterious Cost of Carrying Inventory” and “What Does it Cost You to Buy”.  By utilizing an accurate EOQ you will ensure that you are buying the quantity that will maximize your corporate profitability.

You might think it is always a good idea to maximize profitability.  That is buying a larger quantity at a lower total unit cost to maximize profit dollars.  And it probably is… if you have the cash to do so.

However in today’s economy we see many companies willing to sacrifice some profit dollars in order to invest smaller amounts in inventory.  If you find yourself in this situation, closely examine the EOQ quantities calculated by your computer system in terms of the day’s supply of inventory.  Compare the results to the value of the product sold or used during the order cycle for each supplier.  The order cycle (also known as the review cycle) is the typical length of time between replenishment shipments being received from the vendor.  For example you may receive shipments from the primary vendor of a particular product line every 10 days.  If you include this item on each order you can order a ten day supply and have enough inventory on hand to meet your customers’ expectations of product availability.

This order cycle reorder quantity:

·         is usually less than the EOQ quantity and so will reduce cash outlays for inventory and increase inventory turnover (your opportunities to earn a profit)

·         does not affect customer service since it does not affect either anticipated lead time usage or safety stock quantity.

Replacing the EOQ with the order cycle quantity for many items may substantially reduce the amount of cash  invested in inventory. This may be just the remedy for a company having cash flow challenges!

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Excerpt from http://raiseyourprices.com/

If you can successfully raise your prices, it will put more cash in your pocket than anything else you can do — including selling more products. Why? Because every cent of a price increase is pure profit. For example: a 1% price increase would results in a 12% profit increase for most large corporations, given their profit margins. That’s because you dont’ have any additional costs associated with a price increase. A 5% price increase? That’s a 60% increase in profits.

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Excerpt from the book, “Pricing for Profit”

“The key takeaway is to set prices by thinking like a customer. This involves understanding what next best alternatives customers have and then setting a price that reflects the value of your product or service relative to this next best alternative. For stores with several locations, this usually involves setting different product prices at each store – the next best alternatives (hence the value of products sold) – that customers have are usually different at each location. Sure, it is tedious to spend a day or two to re-price products to match the value that they deliver. However if you can increase your company’s operating profits by 10% or more as a result of two days of work, it’s worth it. Best of all, prices can be changed on Sunday night and new profits will start rolling in on Monday morning.”

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Six Myths About China | Articles | Manufacturing Outsourcing Supply Chains.

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Rethinking Manufacturing Strategy | Articles | Manufacturing Outsourcing Supply Chains.

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This article really got me thinking. I was inspired to reflect on the level of complexity involved in achieving excellence through the process of preparing a product from the raw materials stage through production and finally into my customer’s hands. Enjoy!

BY SIMON BRAGG, JUNE 20, 2002, ARC INSIGHTS 2002-26E

Summary
Here are our top 10 questions that determine if your IT systems hinder your supply chain performance. The best companies in your industry should answer with a straight Yes to these questions. Take this test, and discover if your current investment in IT is delivering the value for best-in-class.

Analysis

1. Are sales, marketing, production, logistics, and suppliers working from the same demand forecast?
“One number planning,” is a sign of excellence. Poor companies produce a sales forecast that is a “tough but achievable” target for the sales force. Production doesn’t believe this forecast, so it generates its own, which usually means large batches to reduce manufacturing costs. Logistics is left to deliver whatever sales manages to sell. Finance doesn’t believe the production or the sales forecast, so it creates its own to manage the cash. Excellent companies generate a single forecast, and gain agreement, feedback, and co-ordination from sales, production, suppliers, and customers.

2. Have you eliminated all rekeying of data?
There should be no need to rekey data in the process of taking a customer order, and issuing production, purchasing, and transport orders. Rekeying data slows execution, adds cost and creates errors. Although it is feasible to integrate customer orders directly into the transaction processing system, few manufacturers achieve this level of integration. Similarly, relevant information in most purchase orders should be shared electronically with your suppliers.

3. Do your delivery lead times reflect available capacity?
A worst practice is to quote a standard lead time, such as two weeks, regardless of the customer or order size. A better practice is to allocate unallocated products from the master production schedule to each customer, a process termed availability to promise. The best practice process is capability to promise, which automatically calculates a delivery date by identifying spare capacity, materials, materials in production, and material purchase orders in the existing, committed production plan.

4. Are all production plans mathematically “optimized”?
For the last 20 years, MRPII has been the standard method of production planning. However, MRP II does not find the plan that minimizes production costs, maximizes customer service metrics, or most profitably utilizes limited resources. MRP II cannot optimize production sequences, schedule bottlenecks to operate at full capacity, or identify least cost routes.
Optimization involves searching a large number of feasible solutions to identify the best. The appropriate optimization algorithm depends on the problem. The main techniques are mixed integer linear programming, genetic algorithms, or constraint programming.

5. Is your part numbering consistent across every system?
Different systems, plants, and countries often use different part numbers to represent the same item. Yet, differing parts numbers hide similarities between components, sub-assemblies, and final products. Gaining economies of scale through standardizing on one common part numbering genealogy will go a long way in centralizing supply chain planning and purchasing across multiple plants, leading to better production optimization, supplier consolidation, and ultimately improved responsiveness to customer and market needs.

6. Do your key metrics measure total SC performance?
If you cannot measure supply chain performance, you cannot control nor improve performance. Metrics such as the Supply Chain Council’s “perfect order fulfillment” reflect performance across order management, fulfillment, and accounting functions. However, many supply chain managers carefully select and define metrics that make them look good, often arguing that they face special conditions that require special metrics. The trouble this creates, though, is that the head-office cannot compare performance geographies as easily as it compares, for instance, financial performance. It also becomes harder to transfer best practices across divisions and geographies.

7. Do you know how much product your key customers consumed today?
A key customer consumes more than 10 percent of your production. That customer may calculate their order quantity based on an Economic Order Quantity calculation. If so, this amplifies any variability in demand the customer reports back onto your plant. If you know your customers’ actual daily consumption of your product, then you are in a much better position to replenish their stocks, minimize your transport costs, and manage the utilization of your plant.

8. Have you Consolidated and controlled transportation procurement, planning, and execution processes and technology?
Traditionally, companies have taken a fragmented approach to transportation management. Inbound, outbound, domestic, and international moves have generally been treated as independent activities, thereby forfeiting potential efficiencies gained by taking a more holistic perspective, an approach that many leading companies are now adopting. By centralizing and integrating transportation processes and technologies, companies are able to reduce costs and improve service levels by (among other things) enabling better compliance to routing guides, converting more LTL shipments into less expensive truckload shipments, and creating multi-stop and continuous move shipments.

9. If a process breaks, does the responsible manager discover the problem that day?
If a supplier cannot deliver the promised quantity, or a machine, truck or system fails, then the responsible manager should be informed that day. If the manager is unavailable, the problem should be escalated. Rapid dissemination of problems grants managers more time to solve problems, and widens their choice of options. In poorly managed companies, managers often only discover problems when promised materials or sub-assembles don’t arrive in their department on the promised date, which is simply too late by today’s standards
.
10. Does your pricing dynamically depend on capacity utilization, competitors’ actions, and the individual customer?
Traditionally, pricing and discount structures are rigidly enforced and slow to change, or each salesperson negotiates on a case-by-case basis, leaving money on the table. Yet dynamic pricing is common in the 3PL, airline, and hotel industries, as small sustainable price increases go straight to the bottom line. But if fixed costs are high, capacity utilization is low, and the prospect doesn’t fully value your product offering, then temporary discounting enhances profits. Dynamically calculating the most appropriate price is potentially a technology with extremely rapid payback.

Recommendations

These questions reflect the main supply chain technologies and best practices that are being implemented today. Now that you’ve taken the test, how many times did you answer yes?

If you scored under 3, the good news is that there is plenty of opportunity.

A score of between 4 and 6 reflects, we believe, pragmatic use of available.

Scoring 7 or 8 reflects early adoption of most of the useful supply chain.

A score of 9 or 10 indicates your company is at the leading, probably the bleeding, edge of technology adoption.

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I am impressed with the contribution of dashboards toward expediting decision-making for corporate executives. I was inspired by this article to research dashboards and their underlying theory in greater depth. Enjoy!

A “dashboard” pulls up everything the CEO needs to run the show.

It was New Year’s Eve, 2003, and Oracle Corp. (ORCL ) CEO Lawrence J. Ellison was on his honeymoon. He and his bride, romance novelist Melanie Craft, were relaxing on his 243-foot Katana yacht off St. Barts, the Caribbean island known as a haven for movie moguls and rock stars. But Ellison, for the umpteenth time, couldn’t help himself. He climbed to his office on the upper deck of the Katana, fired up his computer, and logged on to the Web site of a small company called NetSuite Inc. It was the last day of the fiscal year, and Ellison, the co-founder of NetSuite and its largest investor, needed to know if the startup was going to meet its largest investor, needed to know if the startup was going to meet its numbers.

Before the Internet, Ellison says, taking the pulse of a company was sort of ridiculous. To get the latest sales information, he would call several people and wait days for them to process financial reports that often were out of date by the time he got them. “You would use your cell phone and work on feelings,” he says.

But thanks to a new Web-based management tool known as a dashboard, Ellison had the information he needed in seconds. Like the instrument panel in a car, the computer version displays critical info in easy-to-read graphics, assembled from data pulled in real time from corporate software programs. Logging on to his dashboard for NetSuite, Ellison reviewed the financial data and saw surprisingly strong sales. He quickly called NetSuite CEO Zachary A. Nelson. Recalls Nelson: “The first thing he screams is: ‘Are the numbers on my dashboard right?”‘ Nelson looked at his own dashboard, but his sales data were lower. So he pushed a refresh button. “The information came up with the new orders, and it was the exact same number,” says Nelson. “It was a very big high-five call.”

Since the advent of the mainframe in the 1950s, companies have dreamed of using computers to manage their businesses. But early efforts came up short, with technology that was too costly or too clunky. Now, thanks to the Net and dashboards, those dreams are starting to come true. Forrester Research Inc. (FORR ) analyst Keith Gile estimates that 40% of the 2,000 largest companies use the technology. Some of the most prominent chief executives in the world are believers, from Steven A. Ballmer at Microsoft (MSFT ) and Ivan G. Seidenberg at Verizon Communications (VZ ) to Robert L. Nardelli at Home Depot (HD ). “The dashboard puts me and more and more of our executives in real-time touch with the business,” says Seidenberg. “The more eyes that see the results we’re obtaining every day, the higher the quality of the decisions we can make.”

The dashboard is the CEO’s killer app, making the gritty details of a business that are often buried deep within a large organization accessible at a glance to senior executives. So powerful are the programs that they’re beginning to change the nature of management, from an intuitive art into more of a science. Managers can see key changes in their businesses almost instantaneously — when salespeople falter or quality slides — and take quick, corrective action. At Verizon, Seidenberg and other executives can choose from among 300 metrics to put on their dashboards, from broadband sales to wireless subscriber defections. At General Electric Co. (GE ), James P. Campbell, chief of the Consumer & Industrial division, which makes appliances and lighting products, tracks the number of orders coming in from each customer every day and compares that with targets. “I look at the digital dashboard the first thing in the morning so I have a quick global view of sales and service levels across the organization,” says Campbell. “It’s a key operational tool in our business.”

The technology is particularly valuable to small companies, since most of them couldn’t afford sophisticated software in the past. Up until about five years ago, dashboards had to be custom built, so the expense could run into the millions of dollars. Now, NetSuite and others offer products that run $1,000 to $2,000 a year per user. “NetSuite brought on a total change in the way the company works and thinks,” says Nate Porter, vice-president of American Reporting Co., a Kirkland (Wash.) provider of credit reports and other mortgage services.

PRIVACY CONCERNS 
Still, dashboards have drawn some flak. Critics say CEOs can miss the big picture if they’re glued to their computer screens. GE agrees with that point. While business unit chiefs such as Campbell are active dashboard users, CEO Jeffrey Immelt is not, since he focuses on issues such as broad strategy and dealmaking that the technology can’t yet capture.

Other critics fear dashboards are an alluring but destructive force, the latest incarnation of Big Brother. The concern is that companies will use the technology to invade the privacy of workers and wield it as a whip to keep them in line. Even managers who use dashboards admit the tools can raise pressure on employees, create divisions in the office, and lead workers to hoard information.

One common concern is that dashboards can hurt morale. Consider the case of Little Earth Productions Inc., a Pittsburgh clothing manufacturer. The company uses NetSuite’s tools to monitor the amount of business each salesperson has brought in and then displays it publicly. “You do feel bummed out sometimes if you are low on the list,” says Ronisue Koller, a Little Earth salesperson.

Those pressures can lead to even bigger disruptions. NetSuite CEO Nelson says his dashboard allows him to read every e-mail sent by the sales staff and to inspect the leads of each salesperson. “It’s frightening,” he says. And it can have serious consequences. Once a month, Nelson plays “lead fairy” and looks at what sales leads have been followed up on and which ones haven’t. One salesman quit when Nelson wrested away his sales leads that were not being used and gave them to others who were out of leads. “This raised enormous hackles in the company,” says Nelson. “That’s fine with me because he wasn’t doing his job anyway.”

Still, most management experts think the rewards are well worth the risks. They caution that executives should roll out the systems slowly and avoid highlighting individual performance, at least at first. They also underscore the need for business leaders to spend time up-front figuring out which metrics are the most useful to track. But that’s a question of how to use the technology, not whether to implement it. “You can’t manage something you can’t measure,” says Ken Rau, managing partner at Bay Area Consulting Group LLC in San Francisco. “Dashboards are one of management’s key techniques to make sure an organization is performing according to its objectives.”

The intellectual foundation for dashboards was laid down in the late 1970s with the academic field of decision support systems. DSS introduced the idea that computer systems could be used to aid the process of decision-making. But it wasn’t until the late 1990s, as the Internet linked up computers around the world, that companies began building the dashboards of today. In 1998, GE was one of the first companies to cobble together its own proprietary technology. The trend picked up steam after the recession of 2001, when efficiency became a priority. In the past few years, a new wave of software makers — including NetSuite, Salesforce.com (CRM ), and Hyperion Solutions (HYSL ) — have begun making dashboards that are even cheaper and easier to use.

A MUST-HAVE 
Netsuite, based in San Mateo, Calif., was founded in 1998 by Ellison and Evan Goldberg, a former top software engineer at Oracle. In 2002, Nelson took over the company after leaving Network Associates. Today the company offers everything from dashboards to marketing software to tools for setting up an e-commerce Web site. NetSuite claims more than 7,000 customers, most of them small and midsize businesses. In 2005, it was the second-fastest-growing technology company in North America based on five-year sales growth, according to consultant Deloitte. And last year it was on track to hit $70 million in sales, up from $41 million in 2004.

One big fan of dashboards is Microsoft Corp. (MSFT ), which of course makes plenty of business software itself. Jeff Raikes, president of the Microsoft division that makes its Microsoft Office software, says that more than half of its employees use dashboards, including Ballmer and chief software architect William H. Gates III. “Every time I go to see Ballmer, it’s an expectation that I bring my dashboard with me,” says Raikes. Ballmer, he says, reviews the dashboards of his seven business heads during one-on-one meetings, zeroing in on such metrics as sales, customer satisfaction, and the status of key products under development.

As for Gates, Raikes says the Microsoft founder uses a dashboard during his “think week,” when he leaves the office and reads more than 100 papers about the tech industry prepared by employees. “He uses the dashboard to track what he has read and the feedback and actions that should be taken,” says Raikes.

TROUBLESHOOTING 
Dashboards are a natural for monitoring operations. In manufacturing, GE execs use them to follow the production of everything from lightbulbs to dishwashers, making sure production lines are running smoothly. In the software business, Raikes uses his dashboard to track the progress of the upcoming version of Office. Shaygan Kheradpir, the chief information officer at Verizon, has on his dashboard what co-workers call the Wall of Shaygan, a replica of every single node on the telecom giant’s network. All green is good. Yellow or red merits a click. Red means an outage somewhere. “It makes you move where you need to move,” he says.

Dashboard technology can help keep customers happy, too. Before NetSuite, American Reporting’s Porter says customer-service reps just answered the phone and had no place to store client requests. Now the company’s entire customer-service team uses the software. As a result, customer-service managers can see who is responding to calls. And service reps have access to every repair ticket, making it easier to handle customer problems. “It allows us to compete against some of the bigger boys,” says Porter.

American Reporting isn’t the only small fry that’s benefiting. Jerry Driggs, chief operating office of Little Earth, took four months last winter to move his business onto the NetSuite system. Little Earth sells funky eco-fashion products, such as a handbag made with recycled license plates. Today half of the company’s 50 employees use the system to manage their production, sales, and financial operations. “Once you see it is so intuitive, you wonder how we ran the business before,” says Driggs.

In fact, Driggs ran the business by the seat of his pants, and it showed. Because the company had no system to measure its production requirements or level of raw materials, much of which came from China, it took about six weeks to make and ship a handbag. And Little Earth constantly struggled with cash problems because Driggs would often buy more trim pieces and twist-knob closures than he needed. “You used to see dollars sitting on the shelves,” he says. Now, using NetSuite, Driggs can monitor his purchase orders and inventory levels, and the system even alerts him when he is running low on closures and other parts. The result: Little Earth has slashed its shipping time to three days. “All of those things that used to drive us crazy are literally at our fingertips,” says Driggs.

If it’s near the end of a financial quarter, Oracle’s Ellison tracks his customers like a hawk. “I want to know what our five biggest deals are three days before the quarter closes,” he says. “I look at the [dashboard] several times a day. So much of our sales activity gets compressed into a few days.” Ellison will then call the companies himself or figure out another way to seal the deal.

Since his honeymoon two years ago, Ellison has become more convinced than ever that dashboards are the way of the future. He just wishes more of his employees thought the way he does. One continuing frustration is that although all of Oracle’s 20,000 salespeople use dashboards, Ellison says some 20% of them refuse to enter their sales leads into the system. Salespeople don’t want to be held accountable for a lead that isn’t converted into a sale. That makes it hard to get a true picture of the demand for Oracle’s products.

Ellison has considered refusing to pay commissions on a sale if the order is not entered into a dashboard, but for now he thinks such a move might prove to be a bit draconian. “The salespeople are the last of the independents,” says Ellison. “They think their Rolodex is private.” Even Ellison, one of the world’s richest men, concedes that technology — and the power it gives him — has it limits. “People have to be persuaded that it’s right,” he says.

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We couldn’t be more excited. In just one week, we’ll be hosting the first in a series of events we’re putting together with Motorola and SmartTurn on inventory management.

Larger enterprise companies have been benefiting from these kinds of solutions for years, but implementing them on a smaller scale has been difficult for small to mid-sized manufacturers and distributors in the past. Keeping up with the pace of new technology can be a challenge during a time when many organizations are trying to recover from their worst year on record.

Our main goal is to bring technology experts and business leaders together in a forum for discussion and discovery. The new technology that’s emerging, like SmartTurn’s on-demand inventory and warehouse management solution, doesn’t rely on expensive hardware purchases and long, tedious installations like the older solutions did. This event creates a space for manufacturing and distribution business leaders to bring their questions to the leaders in warehouse technology innovation and explore the recent advances together.

Future events will focus on technologies like EDI (Electronic Data Interchange), manufacturing software and how dashboards can help businesses implement the balanced scorecard.

When: Friday, March 12, 2010 at 11:30am PT

What:
Attendees will learn how to:
• Increase accuracy to 99%
• Increase speed and visibility
• Gain the ability to handle backorders
• Reduce costs of rush shipments
• Reduce returns
• Lower carrying costs
• Increase profits

Who:
• SmartTurn, , the leading On-Demand Inventory and Warehouse Management System (WMS) provider
• Motorola
• aimINSIGHT
• Zebra

Where:
235 West 140th Street, Los Angeles, CA 90061

Register Here

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