20 eeckhoudt end to end supply chain transformation

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Supply chain transformation

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  • 2010 Supply Chain Council. ALL RIGHTS RESERVED. | < filename > | Slide 1 | November 2, 10

    End to End Supply Chain Transformation

    Jan Eeckhoudt Lean Six Sigma DPC, DuPont

  • 2 Contents

    1. Introduction to DuPont and DuPont Performance Coatings 2. SCC and DuPont 3. Project DELIVER

    Objectives Plan, phases Approach

    4.Workstreams - Impact PRODUCT CUSTOMER ORGANISATION NETWORK TRANSPORT

    5. Looking forward 6. Key Success Factors & learnings

  • 3 DuPont Company Vision

    To be the world's most dynamic science company, creating sustainable solutions essential to a better, safer and healthier life for people everywhere.

  • 4

    DuPont in 1802 DuPont in 2010

    58,000 employees > 210 sites > 70 countries Hundreds of thousands of DuPont products and customers $26.1B in sales (2009)

    40 employees 1 site 1 country 1 product 12 customers $15,116 in sales (1804)

  • 5

    DUPONT PERFORMANCE COATINGS

    $3.4 B

    DUPONT ELECTRONICS & COMMUNICATIONS

    $1.9 B

    * Includes $.1B in other sales including Applied BioSciences. Total company sales exclude transfers.

    DuPont 2009 Sales by Segment - $26.1 (*)

    DUPONT SAFETY & PROTECTION

    $2.8 B

    Protection Technologies Building Innovations Sustainable Solutions

    DUPONT AGRICULTURE & NUTRITION

    $8.3 B

    Pioneer Hi-Bred Crop Protection Nutrition & Health

    DUPONT PERFORMANCE MATERIALS

    $4.8 B

    Performance Polymers Packaging & Industrial

    Polymers

    DUPONT PERFORMANCE CHEMICALS

    $5.0 B

    Titanium Technologies Chemicals & Fluoroproducts

    Core Markets: Production Agriculture Food & Nutrition Products

    Core Markets: Consumer Electronics Advanced Printing Photovoltaics Displays

    Core Markets: Construction Specialties Industrials & Chemicals

    Core Markets: Automotive OEM Collision Repair Industrial Coatings

    Core Markets: Automotive Packaging Electrical/Electronics Construction Consumer Durables

    Core Markets: Industrial Personal Protection

    Construction & Industrial Military & Law Enforcement

    13 businesses

  • 6

    In 2009, 30% of sales were in Emerging Markets* *Refer to the companys website for a definition of emerging markets.

    2009 Sales by Geography $26.1B

    2009 Company Sales

  • 7 Aligning Strategies with Megatrends

    Market Opportunities

    More food Better food

    Alternative energy solutions Energy efficiency Renewably-sourced materials

    Workplace safety Personal protection Environmental sustainability

    Infrastructure Energy Materials applications customized for local markets

    Megatrends

    Increasing Food Production

    Decreasing Dependence on Fossil Fuels

    Protecting People, Assets & the Environment

    Growth in Emerging Markets

    Strategies

    Grow production agriculture

    Photovoltaics & Biofuels Lightweighting vehicles Accelerate conversion to bio-based raw materials

    Accelerate innovation pipeline Strategic acquisitions Geographic expansion

    Increase local application development Drive further penetration

    The Needs of the World Drive our Science

    More than 75% of R&D is directed toward megatrends

  • 8 DuPont Performance Coatings

    DuPont Performance Coatings serves the transportation industry Aircraft / Aerospace Automotive Commercial Recreation & Sports Vehicles

    DuPont Performance Coatings Mission in E/MEA We will safely, ethically, and respectfully help our customers be successful by significantly improving our Quality & Supply chain responsiveness while delivering business innovation.

  • 9 DuPont Performance Coatings

    Automotive OEM Coatings: DuPont Automotive Systems is the largest global manufacturer of automotive OEM coatings providing technologically sophisticated and environmentally responsible coatings. Paint & Coatings for Metal Exterior, Plastic Exterior and Interior

    Vehicle Refinish: DPC Refinish Systems is the largest global manufacturer of coatings for aftermarket car repair. Spies Hecker , Standox , DuPont Refinish

    Powder Coatings: DuPont is the second largest world-wide manufacturer of powder coatings offering a complete product range including polyurethane, acrylic and thermoplastic polymers.

    DuPont Nap-Gard Functional Coatings, Alesta Decorative Coatings

  • 10 DuPont Performance Coatings

    Electrical Insulation Systems

    For many years, DuPont have been providing the electrical insulation market with Wire Enamels, Impregnating Resins and Core Sheet Varnishes now all combined under the single brand name Voltatex. The DuPont Voltatex products create value for the customers as they evolved from three complementary strategies: reducing environmental footprint, driving break-through product innovation and creating total system solutions.

  • 11 DuPont Performance Coatings

    Commercial Transportation

    DuPont offers the commercial transportation industry a wide variety of products ranging from plastics and polymers to paints and car covers.

    DuPont is a leading supplier of paint and finishes to over the road heavy duty truck companies, railroads, fire & emergency equipment, and fleets of delivery vehicles. DuPont's product offerings help to protect and enhance the performance of commercial transportation vehicles and personnel.

    Imron , Centari ,

  • 12 DuPonts Journey

    Optimizing The Sustainable Safe Production Of The Molecule

    Competitive Imperative Strategic Supply Chain Capability

    Effective and Efficient Advanced S&OP Business Process

    Demand Driven Enterprise

    Market Driven Science Company

    &

    &

    &

  • 13 SCC Methods and SCOR support DuPonts Supply Chain Development

    Enable

    Metrics & Diagnostic

    s

    Benchmarking & ScorCards BPM

  • 14 SCC & DuPont

    Getting Started 2003-2006 Supply Chain Transformation Vision & Roadmap Metrics for awareness Independent projects Total Company Benchmark

    Development of a Standard Approach to Supply Chain Management 2006-2009 Deeper use of metrics automation and analytics Major projects Deliver back to Plan Supply Chain Excellence Path

    Implementation 2010 + BPM SCOR based, technical model Supply Chain Benchmarking / Segmentation SCOR Projects Integrated into Continuous Improvement Integration with S&OP, Product, Demand, Supply People, Process and Tools Integration to implement future state

  • 15

    The scene at start: End 2007 DPC had gone through many transitions and was falling short against benchmarks for service & cost. Customer service performance for the supply chain was not satisfactory for DPCs management or customers, FPDE & WC was too high.

    Manufacturing Supply Chain Planning

    Sales and Customer

    Management

    1. Supply Chain Cost not reflected

    in Customer Policies

    2. ATP process broken

    3. Flawed replenishment

    model

    5. No MPS/MRP

    -visibility -trade-offs

    4. No use of / adherence to

    stock triggers

    6. Poor adherence to plan and high

    variance

    Benchmark Scorecards & Assessment interviews

  • 16

    The Deliver project was tasked with a holistic review of the European DPC supply chain

    Address the holistic deliver process

    to identify and execute specific projects that prioritize, optimize and enable project work underway

    .to yield improvement in: on-time deliveries, working capital (inventory) and FPDE.

    Build out a vision and multi-generational plan for DPC Europe

    Focus on Refinish, OEM, and Industrial Liquids [but excludes Industrial powders]

    Remit & Scope

    On-time and in full delivery performance target: 10% point improvement in 2008 and another 5-10 points in 2009-2010 (based on deliver to request).

    Secure finished product distribution expense reductions... estimated at 15%-20% Finished Product Distribution Expense

    20% Inventory reduction

    Benefit Aspiration

  • 17

    2008: We set up a project (using Six Sigma DMAIC method)

    Approach: Deliver Improvement Programme

    Define and Measure (4 Weeks)

    Baselining

    -Product flow -Process maps -Cost -Orgn -Interfaces -Hypothesis development

    2 Capability & Organisation Assessment -5-level charts -Interviews -Orgn comparison

    3

    Bench-marking

    -Costs -Service Levels -Operational -Process -Policy

    4

    Analyse (5 Weeks)

    Initial Opportunity Identification -Gap analysis -RCA

    5 High Level Design

    -Process / Org redesign -Bus. case development

    6

    Improve (Design) (4 Weeks)

    Implemen-tation Planning

    -Socialisation -Impn planning

    7 Project Setup

    -Stakeholder Interviews -Review of previous studies -Agree timeline and scope

    1

    I II III Control

    IV

    Maintain, Monitor & Enhance

    9

    Detailed Design and Imple-mentation

    8

    Improve (Implement)

    Deliver project Review

    April 11th / 23rd

    Analysis phase Review

    March 19th 2008 2010

    Critical to identify pain points & mid-term improvements and get fast return on investment.

  • 18

    and fully delivered its remit during these three phases

    Address the holistic deliver process

    Identify new projects and enable project work underway

    Build business cases for each initiative

    Create ownership and implementation plans

    Secure a 10 point improvement in 2008 on time delivery

    Obtain FPDE reductions

    Initial Objective How have we done? Full review of SCOR processes and policies, network and logistics for DPC

    Identified 5 key workstreams, with 14 major initiatives, ... many more

    Cases built and validated totalling in excess of initial expectations

    Project management proposal complete to enable execution

    Project targets 15 20% FPDE and 20% working capital

    Project Review

    Status

    Plan for minimum 10 point improvement in OTIF in 08 with additional 5-10 points in 09

  • 19

    Deliver created 5 workstreams with 14 initiatives & +60 projects

    Product

    Balance supply and demand early and in the right place

    Create stock targets that account for real volatility

    Reduce volatility

    SKU rationalization

    Network

    Review warehouses across DPC and then

    Close those with overlapping delivery areas

    and configure the remainder according to customer demand

    Finally optimise supply routes

    Customer

    Create customer segmentation and then differentiate supply chain policies accordingly

    Ensure customer delivery processes drive SAP not the other way round

    Transport

    Impose central management on haulier purchasing

    Tailor transport contracts to the demand profile of the business

    Distinguish between transactional and cooperative relationships with transport providers

    Organisation

    Allow supply chain to focus primarily on cross-site planning

    Where ever possible ensure supply chain activities operate across DPC

  • 20

    DPC OEM Refinish Industrial

    Business

    Block of analysis

    Projects

    Product

    Network

    Customer

    Transport

    Organisation

    X

    Organized around 5 workstreams across 3 segments or at DPC level

    X

    X

    X

    X

    X

    X

    X

    X

    X X

    X

    X

    ... shock for the segments...

  • 21 PROJECT DELIVER : based on SCOR

    Assess perform

    ance

    Manage data

    Manage com

    pliance

    Improve supply chain

    Establish & m

    anage rules

    Enter order

    Reserve inventory &

    set delivery date

    Consolidate &

    build loads

    Pick & pack product

    Ship & invoice

    Process inquiry

    Detailed

    prodn schedule

    Make

    Source raw m

    aterials

    Source carriers

    Plan source raw

    materials

    Plan deliver

    Plan demand

    Plan make

    Plan supply chain

    Enable Plan Source Make Deliver

    EP1 EP2 EP3 EP3 EP9a D1.2 D1.3 D1.1- D1.6

    D1.8- D1.10a

    D1.11- D1.15 M2-6 M1.1 D1.7a P3

    P1.2 -P1.4 P2 P1.1 P4

    Improve Systems

    Data Accuracy

    10 Simplify Product

    Slate

    7 Improve Forecasting

    3 Improve Inventory

    Management

    2

    Improve MPS Process 1

    Define Resin Sourcing Process

    S1-6

    6 Manage Production Variability

    4 Improve Customer Service

    Rules

    D1.1

    Warehouse and

    transport

    8 Cycle Stock Mgmt

    5 9

    Full review of SCOR processes and policies, network and logistics for DPC

  • 22 Product Workstream

    Strategic Planning

    Business Planning

    Master Scheduling

    Master Production Schedule

    S&OP

    Supply Plan

    Plant and Supplier Scheduling

    Execution

    Material Requirements Planning

    MIX: disaggregate

    level - end item

    Capacity Requirements Planning

    Rough Cut Capacity Planning (RCCP)

    Resource Requirements Planning Forecasting

    And Demand Management

    Input/ Output Control and Operation Sequencing

    CAPACITY MANAGEMENT DEMAND

    PRIORITY SETTING

    FEEDBACK

    Volume, value: product

    family level

    = within project scope

    Goal: Design & Implement Integrated Planning Levels

  • 11/2/10

    23

    Linked with Integrated Business Management long term Planning

    Supply & Sourcing/Logistics Sales &

    Marketing

    Product Development

    Technical Content Assessment

    Process Tools

    Technical Content Assessment

    Process Tools

    Technical Content Assessment

    Process Tools

    Mindsets & Behaviors (not part of Deliver)

    Managing Process

    Capability Building

  • 24 The objective: Balancing CSL, WC and SC Cost : clearcoat example

    Customer Service Level or cost for Lack of CSL

    Process Total Supply Chain Cost Working Capital

    Total Inventory down 43%

    Safety stocks down 51%

    No customer Shutdowns

    96% Order Fulfillment w/o Expediting

    95% MPS Stability 58% reduction in excess

    stocks

    Reduction of expediting cost

    Balancing Supply & Demand

    How: Forecasting improvement, DIBM, MPS, RCCP & Inv. Opt.

  • 25 Working Capital Reduction 6 months Average inventory level -35%

    6 IDS MMA -12 days

  • 26 Customer Workstream

    Define and introduce of DIFFERENTIATED service level policy Min order quantity Deliver frequency Fixed delivery schedules Surcharges for emergency shipments And having this automated in SAP

    IT optimisation : delivery consolidation 1 shipment for many customer orders optimise warehouse and transportation cost

    drivers

    Result : 1% FPDE reduction Sales-to-cash reduction

    Accounts receivables reduced by >15%

    Touch free transactional processes in SAP

  • 27 Organization workstream

    Challenge:

    755 DPC employees maintain the key supply chain processes across fifteen different organisation structures with many hand-offs & duplication, misalignment and in-efficiency.

    Initiatives:

    Allow supply chain to focus primarily on cross-site planning

    Wherever possible ensure supply chain activities operate across DPC

    Reduce the number of reporting layers

  • 28

    Supply Chain Manager Jeff Serpan (53.1FTE)

    MPS / Supply + Inventory Supervisor

    Hans Verbeek (20 FTEs)

    Supply Planners Wuppertal

    Incl. CS, Export 7 SOX (8 FTEs)

    Supply Planners Mechelen

    Incl. CS, Export & Metrics

    (11FTEs)

    Physical Distribution Supervisor

    Ilse Lazou (14.1FTEs, incl. 1 open, 3HC=1.1FTEs)

    Process & Project Supervisor

    Philippe Rigaux (15FTEs)

    Warehouse Operations Mechelen

    (12.5 FTEs)

    Warehouse Operation

    Wuppertal Team (0.6 FTE)

    Process + Project Team (5 FTEs)

    Refinish Material + Customer Master Data

    (9 FTEs)

    Supply Chain Manager Klaus Rohde (53FTE)

    Planning Manager Martin Rubach (29 FTEs)

    Supply Network Planning Thomas Hahn (9FTEs)

    Produktionsplanung* Michael Wilkesmann (6FTEs)

    Vormaterialsteuerung* Markus Plog (6 FTEs)

    Logistics Manager Werner Recks (22FTEs)

    SOX Inventory Control Specialist

    Melanie Waechter (1FTE)

    Stammdaten Michael Hagemann (7FTEs)

    Container Management Rolf-Guenter Krieger (2FTEs)

    European Warehouses +

    Freight Control U. Adler + S. Kalms (2FTE)

    Dispatching Andreas Schmidt (11FTEs)

    Admin / IT Ralf Dahlhaus (6 FTEs)

    Supply Chain

    Refinish OEM

    Supply Chain Manager Guntramsdorf & Supply Chain Leader

    Industrial Liquids EMEA

    Dirk Verbole

    Planung Stefan Guger

    Strategische Planung /Bestandsmanagement/

    Reporting / SOX

    Susanne Samer

    Operative Planung Edi Ovcak

    Operative Planung Zelle Basecoat

    Edi Ovcak

    Sophie Frhlich

    Operative Planung/Springerfunktion

    Zelle CC/Hrter/Verdnnung/

    Farblose HF Manuela Malek

    Operative Planung Zelle Reiben/ IMRON

    Cornelia Frisch

    Lager/ Versand / Gefahrgutbeauftragter

    Hans Teufelsbauer

    Bestandsmanagement Alfred Prrer

    Petra Heinrich

    SOX / Reporting Claudia Steiner

    Strategische Planung / Controlling

    Susanne Samer

    Site Manager Klaus von Juterczenka

    Regional Supply Chain Manager - DPC Europe.

    Randall K. Willis

    Lager Christian Paukovits

    Versand Sybille Muik

    Versandabwicklung** Fr. Gutschi Fr. Htter

    Fr. Lang Fr. Mikl Fr. Maul

    Schichtgruppe 1* H. Birnbammer (Schichtfhrer)

    H. Zilic

    H. Schnitzer

    Hauptgruppe* H. Kaminsky (Stellvertreteder

    Vorarbeiter, Schichtfhrer)

    H. Goger H. Haag*** H. Probst*** H. Fahnler H. Kberl

    H. Nachtelberger

    Schichtgruppe 2* H. Sassmann (Schichtfhrer)

    H. Breit

    H. Gspurnig

    Vorarbeiter Christian Biricz

    Industrial

    Asun Martnez EMEA 94 fte

    (excl. PoD)

    Edith Gijsbregts

    MECHELEN 54 fte

    + BeNe PoDs

    Torsten Schrauf

    COLOGNE 11 fte

    Loredana Locati

    CAVENAGO 9 fte

    Christian Ekwall

    GOTHEBORG 5 fte

    + Scan PoDs

    Ramm Domingo

    PESCOLA 9+ 4 fte

    Joachim Walbrodt

    PODs

    Miek de Wel

    FRANCE & BENELUX

    10 fte

    Wim Bernaert CE, EE,

    MEA & A 12 fte

    Kathrin Baldzun

    UK & SCAN 6 fte

    Sabine Melis

    CB &Other 5 fte

    Mila Herreros

    DCS 16 fte

    Virgilio Maia

    M.MARTINS 4 fte

    Key Users Other 4 fte

    Geert Van Moer

    IBIP 1 fte

    Manager POD J Walbrodt

    Project & infrastructure P Herzog

    Manager Logistics Germany NW

    M Duwart POD Support RSCAC

    LC Freiburg J Owczaryszel

    +7 LC Stuttgart

    H. Koehler

    +16

    SH Karlsruhe P. Schubach

    +6

    LC Neu-Ulm M. Schneider

    +11

    Project & Infrastructure S. Duehr

    Manager LogistIcs North RSCAN

    U. Drosselmeyer

    SH Saarbruecken H.J. Potthoff

    +4

    LC Koeln R. Welz

    +17

    LC Rhein-Ruhr U. Sperl

    +16

    LC Frankfurt M. Schmidt

    +19

    LC Hagen E. Ebbinghaus

    +17

    O. Benkau

    C. Ebert

    S. Hegemann

    K.Vogeler

    H. Wobedo

    Secretary C. Schmidt

    LC Berlin F. Friedrichs

    +13

    SH Nossen/Dresden K. Seiffert

    +8

    LC Bremen A. Seiderman

    +3

    LC Thorey R Killmann

    +4

    LC Lehrte D Karus

    +14

    SH Regensburg S. Muecke

    +6

    LC Meerane G. Schroeder

    +5

    LC Schweinfurt M. Leuchs

    +7

    LC Rostock M. Guthman

    +6

    SH Muenchen M. Berkenstraete

    +7

    SH Bielefeld E. Althof

    +9

    LC Nuernberg P. Borschel

    +12

    LC Hamburg T. Grothkop

    +14

    LC Magdeburg H.Mews

    +6

    Peter Czisch APC Manager

    CS Leader Rudiger Baier

    Customer Service Improvement Dieter Zander

    Customer Service France Annik Duchee Customer Service Turkey

    Customer Service South Africa

    Team Leader CS Group 1 Stefanie Knaak

    Team Lead CS Group 2 Gabriele Fontaine

    14 CS Agents based on site

    12 CS Agents based on site

    Logistics

    S&L Production Planning

    Mechelen Ref Wuppertal OEM

    Guntramsdorf Ind

    Refinish OEM Industrial

    Sales, Demand

    Annemie Sollie Production Planning, Mechelen

    Hans Asaerts MIXSB + primer

    FP Planning, Scheduling, Scheduling Intermediates

    Jan Bergmann DPC Operations Director, EMEA Andreas Bohlender DPC Operations Manager, Mechelen

    Rita Lauwerts Raw Material Planning

    Li Ma (Temp Contract) Raw Material Planning

    Geert Simons (Project + IBIP Key user) Raw Material Planning

    Derek Tutt Packaging Planning

    Toon Gyssels (Contractor) Outsourced filling / packing / drumming

    Packaging Planning

    Erwin Boons (IBIP Key User)

    Packaging Planning

    Bert Vaes Container Planning + SOX reporting

    OEM FP + other tasks

    Johann Debacker FP Clears/MIXSB OEM

    + Intercompany Resins / Intermediates

    Tessa Jacobs (temp contract) FP Planning Clears REF

    FP planning + scheduling:

    activators, thinners, Cromax

    Sofie Wambeke (Contractor) CSR & Planning Intercompany Products

    Jill Schoenmackers (Temp Contract) CSR & Planning Intercompany Products

    Eva Gellaerts Master data

    SOX Reporting

    Maria Dalemans Batchcard Processor

    Jovan Colans (Temp Contract) Batchcard Processor

    David Claes Projects (IBIP, APO, LEAN, etc)

    Werner Van Beneden Scheduling: Clears / Resins

    Wuppertal Ref 221 RPSL Fertigung 218/222

    FACPAC Fertigung 220 PRIME / PUTTI

    Fertigung 208 ACTIV / THINN / CLEAR

    Abfllung 218 Abfllung 222 Abfllung 220 Abfllung 228

    Fertigung 218/222 MIXSB/MIXWB

    Produktionsplanung

    Abfllung 208

    Abfllplanung Verpackungsdisposition Abfllkoordination

    Produktionsplanung Produktionsplanung Produktionsplanung

    Rohstoffdisposition Rohstoffdisposition Rohstoffdisposition

    Produktionsplanung

    Rohstoffdisposition

    Fertigungssteuerung Fertigungssteuerung

    Fertigungssteuerung Fertigungssteuerung

    Etikettendisposition

    Customer Service

    Refinish OEM Industrial

    15 different organization structures in DPC touching supply chain

  • 29

    Does the organisation

    assure continuity of

    process?

    Process

    Organisation Screens

    Does the organisation

    group appropriately by

    function?

    Does the organisation

    group appropriately by

    location?

    Is the organisation

    sized correctly?

    Does the organisation

    have the right spans of control?

    Does the organisation

    have an optimal upward

    reporting?

    A B C D E F

    Function Location Size Spans Reporting

    We have subjected these structures to six tests or screens

  • 30

    Three pure tone options have become apparent. Option 2, less hand-offs, simplified structure, more 1 DPC.

    Process Level 1 Process Level 1/2 Status Quo

    Option 1: Plan Driven/

    Order Driven

    Option 2: SC Back

    Office Option 3:

    End To End

    Enable

    EP1 Establish and manage rules SC SC SC SC

    EP2 Assess performance SC SC SC SC EP3 Manage data SC/CS SC SC SC EP8 Manage regulatory compliance SC SC SC SC EP9a Improve supply chain S&L/SC/CS SC SC SC

    Plan

    P1.1 Demand planning Sales Sales Sales Sales P1.2-P1.4 Supply chain planning SC/CS SC SC SC P2 Plan source raw materials SC/OPS SC SC SC P3. Plan make SC/OPS SC SC SC P4 Plan deliver (warehousing and transport) SC/CS SC SC SC

    Source S1-6 Source raw materials OPS/SC OPS OPS OPS D1.7a Source carriers S&L/CS S&L S&L S&L

    Make M1.1 Schedule production OPS/SC OPS OPS OPS M2-6 Make OPS OPS OPS OPS

    Deliver

    D1.1 Process inquiry (including complaints) CS CS CS SC D1.2 Enter order CS CS CS SC D1.3 Reserve inventory & determine delivery date SC/CS CS SC SC D1.4 - D1.6 Consolidate & build loads CS/SC CS SC SC D1.8 - D1.10a Pick & pack product S&L/SC CS SC SC D1.11 -D1.15 Ship & Invoice SC/CS CS CS SC

  • 31

    As a result of this analysis we were able to isolate the Supply Chains Organisational Design Principles

    Source: Organisation Workshop involving SC and CSR leads in April 2008

    Themes Principles

    The Supply Chain must be responsive to the businesses

    Within the SC organisation there must be a strong link to the business teams. The people having this role will represent the extended SC (Buy-Make-Deliver)

    The Supply Chain is an end-to-end, cross-site activity with planning at its core

    Master Production Scheduling (MPS) to be done in SC by business short-term and product family mid-term

    MPS to include Raw Material Planning, Production Planning, and Distribution Resource Planning however the changes involving Production Planning should be process-led and gradual

    Detailed Scheduling, and Raw Material call-offs to be done in Manufacturing and across businesses on site

    Whenever possible, the Supply Chain activities will be organised across DPC

    The SC organisation will be evolving to a 1-DPC SC organisation

    A number of discrete activities can be managed across DPC including: Metrics, ERP data, SOX administration, Container management

    The Supply Chain organisation will not replicate roles better performed elsewhere

    S&L to act as a 4PL governed by a SLA and therefore S&L is responsible for contract management and administration

    Customer complaint management is done by the Customer Service team and not in SC

    SC is accountable for the complete Warehouse Network Design. SC should delegate or outsource the day to day execution of Warehouse Operation and Dispatching where practical.

    Customer service restructuring depends on DPCs value proposition to the market

    Supply Chain organizational transformation is not contingent on CS reorganisation

    CS reorganisation will require an in-depth understanding of customer requirements and the need for CSRs to play a sales assistant role

  • 32 Organization workstream

    Warehouse Lead

    Continuous Improvement

    Lead

    DPC SC Planning

    Lead

    Business Link REF

    Business Link OEM

    Business Link IND

    Control & ERP Data L.

    EMEA SC Manager

    CDC

    LW & Consignment

    Master Data Team 1

    Master Data Team 2

    LSS Continuous

    Improvement Team (BB)

    Control Team 1

    Control Team 2

    Container Management

    Reporting Team

    SC Planning MPS 1

    SC Planning MPS 3..n

    SC Planning MPS 2

    SC Planning Resin

    Liquid only Leveraged across DPC

    Commentary

    Requires standardised product hierarchy between three businesses

    Resultant synergies will lead to increased efficiencies through greater scale and lower costs

    One DPC should form basis of end-state business architecture, ensuring strategic alignment of future initiatives

    and to design on a high level the new EMEA SC Organization

    Container Mgt

    Reporting layers were reduced from 6 to 4.

  • 33 However structure is only one part of an organisations DNA

  • 34

    DPC EMEA Target Network Structure (1)

    Note (1) OEM customer required, powder and consignment warehouses are not represented

    Manufacturing site

    Warehouse

    Closing Warehouse

    Multiple waves of consolidation Mostly into the Genk ELC

    UK warehouse closure

    Germany 3 locations

    Portugal

    France 2 locations

    Spain

    Italy

    Network workstream

    All Distribution projects will, by end 10, reduce FPDE by + 17%

  • 35 Transport Workstream

    Central procurement of freight

    Extensive usage of groupage & intermodal shipments

    Consolidation of many small deliveries to one customer delivery address on the same day, to one shipment.

    Techniques to increase the transport loading factor

    Pallet load optimization techniques

    Parcel shipments rather than palletized loads.

    Shipping policies such as min size & frequency

    More robust process to manage and control rush shipments

  • 36 Looking forward

    Simplified Ship-tos

    Closure of Geserick and LMS

    Complete Q4 - 2008 2009 2010

    Delivery Due List Service Policies (Small shipment upcharge)

    Application of analytical safety stock calculation

    Application of analytical safety stock calculation

    SKU rationalization

    Raw / Semi Inventory Reductions

    Russia- Lane effectiveness

    Turkey -Lane effectiveness

    Freight Consolidated Settlement

    ATP -PODs to DRP

    ELC Delivery consol

    Receivables reduction

    Increase in forecast accuracy

    Differentiated service levels

    MPS

    Resin availability

    Production execution to

    Plan

    Carrier Management Small (parcel) shipments

    MTO/ MTS policy change

    NGST Inventory Exposure Reduction

    Central Procurement of Transport

    W1 warehouse closures

    Heated transport

    POD restructuring

    2011+

    Footprint reduction

    Customer

    Transport

    Product Organisation

    Supply Chain Re-organization

    Network

    M&B

    DIBM MPS tools

    AS

    OTIF baseline

    OTIF II

    Pallet Load Opt

    MPS-AS interface

    ATP - STO

    Product Master Data Management

    Rush shipments

    Adv Inv Mgt

    RCCP

  • 37 Key Success factors & - learning

    The engaged, senior, Steering Committee created momentum both inside and outside the project team The team engaged the business and the business engaged the team consistently through all phases

    The project used data and diplomacy to create change

    Projects must be directionally toward the vision (Vision Required) and aligned with the strategy.

    Results must be a COMMITMENT for the project team AND the line

    Watch both the project validations AND the balance sheet, must hot bottom line.

    Progress must be reported via routine reviews attended by key stakeholders, and senior leadership , based on a formal Program Management Office structure Projects touch and interact, strategic decisions allow projects to link, build or detract from each other A long term end-to-end strategic view that does not ONLY focus on pain points & quick hits. Projects must be transformational in nature, major step changes not small increments.

  • 38

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