How to Calculate Total Landed Cost October 30, 2009
Posted by Jeff Fuchs in manufacturing, strategy, supply chain.Tags: manufacturing, outsourcing, supply chain
add a comment
An occasional collaborator of mine, Larry Loucka (a brilliant supply chain consultant, by the way), recently blogged and listed all the many elements of total landed cost. This is one of the better lists I have seen, and I wish more business leaders used it in considering their offshoring strategies. In many cases I have personally seen, decisions to move a product to China, or source a product from India, have delivered negative financial results. In some of these cases, the companies don’t even know it, simply because they are not adding up all the factors.
I am not anti-globalization, per se. I would simply prefer that leaders do all their homework before they make a shortsighted, “me too” decision.
See the list of Total Landed Cost elements here, and see how bad the problem is according to the Aberdeen Group Global Supply Chain Benchmark Report here.
New Measure for Carbon Footprint Inside Supply Chains October 30, 2009
Posted by Jeff Fuchs in green business, supply chain.Tags: green business, supply chain
add a comment
The Green Supply Chain Initiative of the World Resources Institute (WRI) will develop and deploy a new set of accounting tools to measure the greenhouse gas (GHG) impacts of a company’s supply chain and of the products that are sold to customers. The project, which is funded by Walmart, also involves creating a web tool that will bring clarity to the various environmental certifications given to products.
Read the full article here.
Stress Reveals Supply Chain Shortcomings October 6, 2009
Posted by Jeff Fuchs in automotive, economy, supply chain.Tags: automotive, manufacturing, supply chain
add a comment
Once again we are reminded that many flaws in business operations can be masked during the good times, only to become painfully apparent when things get tough. Looking at the recent implosion of GM provides a case study in how many companies saddled themselves with supply chain strategies that were ill conceived from the outset but whose shortcomings became apparent only when stressed.
In the view of Steve Banker of ARC Advisory Group, successful outcomes in supply chain management are achieved by applying sound principles of continuous improvement in an environment characterized by strategic planning, rather than hasty plans conceived in forced urgency.
“Firms with a robust strategic planning process are better equipped to deal with large, unexpected events, like the current global recession… Continuing improvement in the economy mandates a Deming-like ‘continual improvement’ in the quality of supply chain decisions, including frequent re-optimization with market changes.”
Read more on this topic here.
Speaking of Supply Chains, Consider the Benefits of Outsourcing to Domestic Firms October 6, 2009
Posted by Jeff Fuchs in manufacturing, strategy, supply chain.Tags: manufacturing, outsourcing, supply chain
add a comment
While the attraction of lower initial costs is undeniable, many companies are discovering that the actual savings achieved through outsourcing to the Far East can be significantly less than expected. When viewed in the context of robust supply chain design in a turbulent world economy, this fact provides strong incentive to consider looking for strategic partners a bit closer to home.
Outsourcing the manufacturing of electronic equipment to the Far East may seem to be beneficial to U.S.-based original equipment manufacturers (OEMs) because of the lower labor costs; however, Reliable Plant reports that the increased logistics costs tend to increase supply chain expenses.
Also, “cheap labor in China slowly is becoming a thing of the past. Double-digit growth in wages now is the norm, and there is an increase in switching jobs. China’s economy also is growing, so there currently is a shortage of skilled manufacturing, quality control, and middle-management workers—precisely the profile of the worker that is needed in factories turning out high-technology products for American companies.”
For a summary of this article, along with other highlights from APICS, click here.
For the full Reliable Plant article, click here.
CFOs Say Offshore Outsourcing to Decline March 10, 2009
Posted by Jeff Fuchs in economy, supply chain.Tags: economy, offshoring, supply chain
add a comment
In a new survey, chief financial officers at leading U.S. technology businesses say they’re more likely to consider the U.S. as an outsourcing destination for services and manufacturing over China and India in 2009. Already, it appears that technology companies have started to pull back, according to the BDO Seidman 2009 Technology Outlook Survey, an annual survey of CFOs conducted in January. Only 42% of the 100 CFOs surveyed said they have operations outside the U.S., compared to 79% last year.
Read the full article here.
Survey Sees Some Buyers Switching to U.S. Sourcing March 10, 2009
Posted by Jeff Fuchs in manufacturing, supply chain.Tags: manufacturing, supply chain
add a comment
The North American Die Casting Assn. reports that a recent survey of its members reveals a significant majority, 78%, have evidence that buyers of their products are shifting to domestic sources for diecast components. The survey identifies three reasons for these shifts: buyers’ concerns about the product quality, supplier proximity, and overseas logistics.Read the full article here.
Green Journey Needs a Roadmap March 10, 2009
Posted by Jeff Fuchs in green business, supply chain.Tags: green, supply chain
add a comment
An integral part of sustainability initiatives at global organizations is the close examination of their supply chain environmental footprints. Some companies have embarked on fragmented initiatives to minimize their transportation carbon footprint or make their manufacturing plants more eco-friendly. But greening the supply chain must be founded on coherent strategies that examine the tradeoffs between environmental initiatives, profitability, and efficiency across the integrated supply chain.This article in Supply Chain Management Review details aspects of green supply chain practice.
Read the full article here.
Study: U.S. Automakers Need to Change Sourcing Strategy March 2, 2009
Posted by Jeff Fuchs in Lean Thinking, supply chain.Tags: Lean Thinking, supply chain
1 comment so far
- Commitment from the CEO and senior management to establish an atmosphere of trust and transparency with suppliers
- Alignment of strategic goals and open sharing of critical data
- A long-term commitment to developing supplier relationships as an investment and not an expense
- Clarity of purpose between manufacturers and suppliers at the c-level to know precisely what can and cannot be accomplished with each relationship
- Streamlined decision-making
- A drive to understand each other’s business
“While many of these findings may seem like common sense, it runs counter to the very nature of the U.S. automotive sector,” said Frank Smeekes, head of the Automotive Practice for Russell Reynolds Associates.
For anybody that may have missed it, the tenets above are at the foundation of a lean supply chain strategy. Glad to hear that formal studies are now showing that the Detroit Three need lean supply chains!
Read the article here.
Solving the Riddle of Supply Chain Cost Reduction March 2, 2009
Posted by Jeff Fuchs in economy, supply chain.Tags: economy, supply chain
1 comment so far
Unless you are a hermit who has been stranded on a deserted island for the past 12 months, you get it — we are in a recession.Let’s see what all the “smart” companies are doing, in manufacturing and in other industries. Many are cutting payroll, cutting advertising, cutting consulting, and cutting strategic initiatives.
So should you follow along and also cut, cut, cut? No, because this is not a strategy that leads to success. Across the board cuts, without understanding where your company’s real profitability lies, results in average performance at best and leaves your organization wide open to failure at worst. That old saying, “When you do average, you get average” applies more than ever in these volatile times.
Read the article here.
Getting the Green Light March 2, 2009
Posted by Jeff Fuchs in green business, supply chain.Tags: green business, supply chain
add a comment
In the past year, there have been few topics as pervasive in the industrial community as the subject of environmental initiatives. But which industries’ supply chains are actually leading the way? Are the benefits tangible (either immediately or long-term), or is this a matter of corporate responsibility? And if a company is looking to get started with green supply chain strategies, what types of resources might be necessary and where’s the best place to start? These are the questions the Supply Chain Consortium sought to answer in a recent Hot Topic survey. Some of the results were surprising:
- There is no single industry leading the environmental supply chain initiative.
- There is no consistent policy for ROI thresholds.
- It’s not just about the money.
- Organizations appear too internally focused.
- Personnel and Budgetary Considerations Count.
- The Bottom Line: It is Not Too Late.
Read the full article here.
Next Generation Manufacturing Study Kicked Off February 16, 2009
Posted by Jeff Fuchs in survey.Tags: leadership, manufacturing, supply chain, survey
add a comment
The American Small Manufacturers Coalition (ASMC) recently launched a study to assess America’s progress in adopting manufacturing strategies necessary to win in the global economy.The Next Generation Manufacturing Study asks about participants’ current posture in six areas: customer-focused innovation, systemic continuous improvement, advanced talent management, global engagement, extended enterprise management, and sustainable products and processes.
Study participants will receive a customized benchmarking report comparing their progress to the overall results.
Read an overview about the study here.
Participate in the study here.
Of Course Inventories Are Swelling in Long, Slow Supply Chains February 16, 2009
Posted by Jeff Fuchs in Lean Thinking, economy, supply chain.Tags: economy, Lean Thinking, supply chain
add a comment
The LeanBlog notes a recent Wall Street Journal article that observes how inventory is backing up in transoceanic supply chains. Business leaders are frustrated.
To WSJ and business, all I can say is, “Well, duh.”
As the post notes, the WSJ spot quickly turns to the power of information technology as a way out. Blog author Mark Graban then does a great job linking the problems the WSJ article notes to a classic supply chain simulation. Information is not a savior here – a lean supply chain is. Graban goes on to link the article’s main points to good lean practices. Bravo.
Like Mark, I for one hope that the current economic crisis drives business practices a different way in the future. Hopefully, our emergence from this situation will see more companies developing shorter, leaner, more responsive supply chains with good lean accounting practices that show costs more accurately and holistically. While we’re at it, we can build strong, close relationships with companies and countries that have better labor practices, environmental compliance, and product safety.
Read the LeanBlog post here.
Manufacturers Consider Migrating Back to U.S. February 16, 2009
Posted by Jeff Fuchs in manufacturing, supply chain.Tags: manufacturing, supply chain
add a comment
A new study by Archstone Consulting shows that companies are contemplating the re-establishment of manufacturing domestically, amid rising costs and other strategic challenges within the off-shoring model. As companies reassess their manufacturing and supply chain strategies for today’s global economic environment, the trend may create significant job opportunities in the U.S., according to the recent study.The study found that almost 90% of the companies surveyed are considering changing — or have begun changing — their manufacturing and supply strategy and are being more and more selective in making off-shoring decisions. U.S. manufacturers have become increasingly aware of the need for a more sophisticated total cost model that considers factors such as supplier price and terms, delivery costs, operations and quality costs, customer-centric supply capabilities and other situational costs that arise.
Read the full article here.
Foreign Sourcing of Production February 9, 2009
Posted by Jeff Fuchs in manufacturing, supply chain.Tags: manufacturing, offshoring, supply chain
add a comment
Increasingly in recent years, American manufacturers have looked abroad for the manufacturing of goods to be distributed in the U.S. or for parts to be used in goods to be assembled in the United States, and the recent turmoil in international currency and financial markets is not likely to change the trend. There is nothing new about manufacturers outsourcing part or all of the manufacturing process, however, given the increasing tendency to outsource all or part of the manufacturing process, there are some twists and turns which American companies should be aware of when sourcing from foreign countries.
The article applies generically in some cases to companies’ supply chain issues anywhere, but is tuned to highlight concerns for companies considering offshore production.
Taking production offshore is frought with hidden costs. This article does a good job of underscoring many of them. Read it here.
Autonomous Robots Invade Retail Warehouses February 2, 2009
Posted by Jeff Fuchs in Lean Thinking, supply chain.Tags: Lean Thinking, supply chain
add a comment
Whoa. I’m a techno-geek, and pretty hard to impress. But this article in Wired mag blew me away. I had read about the robots in the Staples warehouses, but a static image just doesn’t do this robotic solution justice. The Wired article has an imbedded YouTube video. You have to see this!

Warehouse fulfillment is an operation that sets my teeth on edge as a lean practitioner. I have worked with a few warehousing operations in my day, and the waste of people walking or riding through a warehouse of overproduction is one of the things I would eliminate with the wave of a magic wand, if I could. However, the real world necessity of such operations cannot be denied. Almost as much as warehouses give me the heeby-jeebies are suggestions in lean improvement events that the solution is “automation” or “robots”. Argh. It’s like nails on a chalkboard to me. (By the way, it occurs to me that my daughter will probably never know that sound. But I digress….)
As a lean practitioner and advocate, I think I love robots about as much as this guy:

Anybody detecting a theme this week? Anyway, the benefits touted by the manufacturer of these robots are many:
- Lower warehouse heating and lighting costs
- Better energy efficiency than conveyors
- Lower inventory shrinkage
- Improved safety
- Less walking, lifting by warehouse associates and lower noise
- Better inventory accuracy
I wonder what the upgraded model looks like?

Read the article and see the video here.
The Next Frontier in Cost Control: Quality February 2, 2009
Posted by Jeff Fuchs in manufacturing, supply chain.Tags: manufacturing, supply chain
add a comment
The trade journal Purchasing recently ran a story noting that the financial downturn appears to be spawning a new focus across all industries on The Cost of Poor Quality, or COPQ.It says that surveys and interviews find buyers insisting that “cost of quality” has to be lowered this year, but that won’t happen unless their best suppliers focus on meeting supply contract specifications, on exceeding quality measurement goals and on meeting continuous improvement of deliveries goals.
In other words, buyers want their suppliers to focus on reduced costs-not just lowered prices-as they provide North American manufacturing firms in 2009 with commodities, components and systems. This meshes with American Society for Quality (ASQ) tenets that the cost of quality isn’t the price of creating a quality product or service; instead, it’s the cost of not creating a quality product or service.
The article is extensive, and well-researched.
Read it here.
Redesigning Supply Chain for Sustainability Produces Results February 2, 2009
Posted by Jeff Fuchs in green business, supply chain.Tags: green business, supply chain
add a comment
A new study from Global Commerce Initiative and Capgemini, “Future Supply Chain 2016: Serving Consumers in a Sustainable Way” finds that there is a strong correlation between sustainability and the future supply chain of the consumer products and retail industry. The study presents a new integrated supply chain model that takes into account sustainability parameters such as CO2 emissions reduction, reduced energy consumption, better traceability and reduced traffic congestion, as well as traditional measures like on-shelf availability, cost reduction and financial performance.The study found that the total potential impact of this supply chain redesign is significant, including reduction in transport costs per pallet, reduction of handling costs per pallet, reduction of lead time, lower CO2 emissions per pallet and improved on-shelf availability.
Read the article here, which points to the full report.
Auto Union Chief Presses for Trade Reform January 26, 2009
Posted by Jeff Fuchs in automotive, supply chain.Tags: automotive, supply chain
1 comment so far
United Auto Workers president Ron Gettelfinger has taken aim recently at free trade policies as a factor in the problems that beset the American automobile industry.
“We must take action to fix our broken trading system,” he said in remarks prepared for an automotive conference. “We can no longer afford to have the most open market in the world, while other countries use currency manipulation and non-tariff barriers to keep out US-made products.” Gettlefinger tempered his message by saying that “the UAW is not opposed to fair trade, but it’s time to recognize that so-called ‘free trade’ is a fiction.”Gettelfinger noted further that the deficit in automotive trade alone is expected to hit 109 billion dollars and the US has an automotive trade imbalance with every one of its major trading partners, including Britain, which has a small automotive industry.
I am not quite sure that Gettlefinger is placing appropriate emphasis on the issues here. If we have a automotive trade deficit with every single one of our automotive trade partners, does this imply that every single one of them – including the British – are manipulating their currencies to create a competitive disadvantage for U.S. companies?
Toyotas and other non-American cars are assembled in the U.S. (mostly in the southeast) and use the North American supply chain for most of their parts, like the Detroit Three. How does currency manipulation of the yen or the euro figure into the competitive strength of non-U.S. players in the U.S. auto market?
Certainly, currency issues are a central factor in trade balance. However, Mr. Gettlefinger’s calculus is a bit oversimplified. For a more nuanced example of the factors at play, take a look at the recent Business Week article, The 65 mpg Ford the U.S. Can’t Have, to see some of the confounding reasons why we can’t seem to get a car made here that is double the typical available average new car gas mileage. By attacking trade policy, Mr. Gettlefinger draws attention away from labor components of new car costs.
Gettelfinger did say, though, that his UAW is willing to consider concessions like those spelled out in the terms of the federal bridge loans for GM and Chrysler. However, before the UAW agrees to any kind of wage concessions, he wants to be able to examine the books of Japanese companies such as Toyota, Honda and Nissan to how they calculate labor costs.
I can’t argue with a desire for an apples-to-apples comparison, especially if the government sets competitive benchmarks for the Detroit Three against Japanese producers. It has been well established, however, that the initial quality ratings and assembly times of Japanese versus U.S. automobiles have roughly reached parity in recent years, so the need for Uncle Sam and Gettlefinger to get into Toyota’s books are largely unnecessary, in my mind. The real issues are company overhead, development expense, and employee benefits.
Read Mr. Gettlefinger’s extended comments here.
What are your thoughts on the plight of the U.S. auto industry, the UAW, or trade policy?
Who’s Keeping Score? January 26, 2009
Posted by Jeff Fuchs in supply chain.Tags: supply chain
add a comment
To keep up with how suppliers are performing, many manufacturers have started using “scorecards” to record statistics of their own. However, relatively few have done so in a way that actually generates much useful information, according to Sherry Gordon, president of the Value Chain Group, a supply management and performance excellence consultancy.”Everyone asks what KPIs should be on their scorecard, what everyone else is doing. But in reality, it comes down to what your company needs from the supply chain.”
Read the full article here.
Boeing to Rein in Dreamliner Outsourcing January 19, 2009
Posted by Jeff Fuchs in Lean Thinking, aerospace, supply chain.Tags: aerospace, Lean Thinking, supply chain
add a comment
Business Week reports that Boeing, beset by problems that have delayed commercial deliveries of its 787 Dreamliner into early 2010, is rethinking the global outsourcing model that critics say has caused much of the nearly two-year holdup.
Engineers at Boeing are frustrated by design and production foul-ups that have led the company repeatedly to send staffers out to suppliers to iron out difficulties. The company’s top executives are suggesting they will rely less on their outside suppliers: The company is making plans to bring more work back in-house.
Boeing has attempted to create a “virtual kerietsu” of far-flung suppliers, and to do so in nearly one fell swoop with the Dreamliner. Industry contacts I have spoken with have described how Boeing relied on suppliers for parts in earlier generations, then relied on them for everything the next with the Dreamliner. The effort to create a seamless global supply chain, a “snap-together” airplane, and make Renton Washington a final integration site was an aggressive dream at best. Was it misguided? History will judge.
I have watched this development program with interest. I think back to a lean aerospace summit some years ago where one of the invited speakers, Jim Womack, took the podium and “ripped the attendees a new one.” He bemoaned the heavy lifting that most aerospace leaders had avoided: consolidating to create true lean value streams and tightly integrated supply chains. Needless to say, he was not invited back warmly in later years’ summits. With the 787, I have felt that Boeing was sidestepping Womack’s observations and advice.
Read more of Business Week’s observations here.
Tesco: ‘Wal-Mart’s Worst Nightmare’ January 19, 2009
Posted by Jeff Fuchs in supply chain.Tags: supply chain
add a comment
As Tesco takes on the U.S. market, American companies like Wal-Mart are taking notice-and adopting some of the British megaretailer’s strategies. Wal-Mart has good reason to be nervous. Back home in Britain, Tesco has long outpaced the Wal-Mart-owned discount chain Asda. The British giant currently has 34% market share, nearly double that of Asda. Tesco’s great advantage is some serious data mining.
Read more in the full article here.
Asian Automakers Seeking Alternatives to Weak U.S. Supply Chain January 19, 2009
Posted by Jeff Fuchs in automotive, manufacturing, supply chain.Tags: automotive, manufacturing, supply chain
add a comment
Asian automakers say they are reevaluating their U.S. supply chains out of concern for possibly disruption through bankruptcies in the wake of a sharp drop in auto sales and the financial problems at General Motors and Chrysler. “The supply base is a big concern,” John Mendel, vice president of automotive operations for American Honda.Toyota is identifying suppliers which may be impacted by a failure at one of the Detroit Three. Importing vehicles from Japan is not considered very possible because of the current exchange rate between the yen and the dollar. Toyota has developed scenarios in which it could keep U.S production going, including finding alternative suppliers or “seeking ways to financially assist suppliers and make sure they don’t go out of business.”
Hyundai has already looked into accessing a supply base outside of the United States.
Honda is relatively safe from problems with suppliers linked to the Detroit Three because all of its key suppliers derive about 80% of their business from Honda.
Read the full article here.
Offshoring Fuels the Aerospace Jobs Debate January 19, 2009
Posted by Jeff Fuchs in supply chain.Tags: aerospace, outsourcing, supply chain
2 comments
How outsourcing and the outsourced worker are viewed depends on which side of the issue – and the world – you stand.Is the relocation of work destroying the aerospace industry or creating a global industrial base that is essential to its health? Is a job moved offshore a loss or a gain for the industry? These questions came to a head in 2008 as outsourcing played a role in the collapse of the U.S. Air Force KC-X tanker competition, the unraveling of Boeing’s 787 program and ultimately the strike that idled the U.S. giant’s commercial aircraft production for eight weeks.
Aerospace is not alone in outsourcing, but the issue is far more complex for this industry than for any other. Manufacturers move work to other countries not just to reduce their costs, but to enter markets, spread risk, access funding and fulfill offset obligations.
As the global economic recession tightens its grip and the growth curve turns downward, outsourcing will come under ever greater and more critical scrutiny.
Read deeper analysis in this Aviation Week article.
Read the full article here.
Inbound Transportation and Receiving: Making Material Flow Starts at the Source January 11, 2009
Posted by Jeff Fuchs in supply chain.Tags: supply chain
add a comment
With so many variables and cost drivers, getting a handle on such costs requires a value chain perspective that includes an end-to-end look at transportation. This article focuses on some of the opportunities for improvement and potential savings on the inbound side of the logistics equation. This includes redefining milk runs, cross docking, scheduling deliveries and the intelligent use of technology.
Read the details in the full article here.
Transforming an Adversarial Customer-Supplier Relationship January 6, 2009
Posted by Jeff Fuchs in manufacturing, supply chain.Tags: manufacturing, supply chain
add a comment
Developing a healthy relationship between manufacturers and suppliers is not easy, but critically important in the current economic waters. The manufacturer-supplier relationship is beset by a great deal of friction, the result of decades of mistrust between historically unequal partners. That friction has increased in recent years because of lower margins and greater market pressure; indeed, some manufacturers that were once praised by suppliers for evenhandedness have recently adopted a more aggressive approach.To determine the elements of a successful manufacturer-supplier relationship and the skills needed by leaders working toward or sustaining such a relationship, Booz & Company joined with executive search firm Russell Reynolds Associates to conduct 43 in-person interviews of senior executives at nine major manufacturers and 19 leading suppliers in the United States and Europe. The focus was on the automotive supply chain. These interviews covered the nature of the arrangements between automakers and suppliers, how their relationships have changed over time, and areas in which their partnerships have worked and where there was room for improvement. An analysis of those interviews produced a clear view of the characteristics of a high-performing relationship, the environment necessary to sustain it, and the qualities needed in executives charged with implementing it.
Read the full article in Strategy+Business here.