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Inventory Control Techniques for Manufacturing Industries - 《 制造业库存控制技术与策略 》

Inventory Control Techniques for Manufacturing Industries - 《 制造业库存控制技术与策略 》. Eliminating Your Inactive Stock and Raising Inventory Turnover Rate Through Effective Integrated Supply China Management 通过高效的集成供应链管理，消除呆滞库存，提高库存周转率. Why are we – SCM & Logistics management - existing ?

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Inventory Control Techniques for Manufacturing Industries - 《 制造业库存控制技术与策略 》

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  1. Inventory Control Techniques for Manufacturing Industries - • 《制造业库存控制技术与策略》 Eliminating Your Inactive Stock and Raising Inventory Turnover Rate Through Effective Integrated Supply China Management 通过高效的集成供应链管理，消除呆滞库存，提高库存周转率 Why are we – SCM & Logistics management - existing ? 我们（供应链管理）为什么存在？

  2. 程晓华简介 制造业背景： 哈尔滨科学技术大学 机械工程 学士(双专业) • Daewoo(重工业-DYMIS-II) • Dunham-Bush (中央空调制造) • Castic-SMP (干洗机制造业) • IBM 北京工厂(EMS电子制造服务-SAP R3) • Elcoteq(EMS电子制造服务- BAAN) • Flextronics(EMS电子制造服务－BAAN) 北京大学 光华管理学院 (结业) • 生产计划员 • 物料计划主管/国产化与国际采购 • 采购与物流经理 • 高级物料经理/ISC-集成供应链管理审核员 • 需求与供应链管理经理 • 全球物料管理总监 MBA 主要研究方向与服务范围： － 培训课程：《制造业库存控制技术与策略》- Since 2004 － 咨询业务：集成供应链与物流管理业务流程与组织结构设计、审核与评估( ISC - BPI/BPR )

  3. Contents － 内容 • Why are we SCM existing? – KPIs of Inventory Control 我们为什么存在？－KPI • Why inventory control? － 为什么要“控制库存”？ • Where is the inventory? － 库存在哪里？ • How to do inventory control? － 怎样控制库存？ • Why “more sales” could be “faster to bankrupt” ? － 销售越大，企业倒闭越快？ • Why don’t we get the right parts on hand? － 为什么（物料）该来的不来，不该来的都来了？ • Why over-production is crime? － 为什么说过量生产“罪大恶极”？ • How are organized? – 3P – People / Process / Performance － 我们的组织架构－3P管理 Case 1 - why did we lose this customer? － 案例1－我们为什么丢掉了客户？ Case 2 – why customer is respecting us? － 案例2－我们为什么受到客户的尊重？ Case 3 – is this the right MPS loading ? – 这是正确的MPS吗？

  4. Why are we – SCM & Materials Management existing？ 我们为什么存在？ On-time Delivery 及时交货 Actually 实际上– Less ITO, Less OTD ! 库存周转率越低，及时交货率越是没有保障 Better ITO, Better OTD ! 库存周转率越高，及时交货率越高 Better OTD, Better ITO ! 及时交货率越高，库存周转率就越高 Inventory Turn-over 库存周转率 Excess & Obsolesce 呆滞库存

  5. Why Inventory Control? 为什么要控制库存？ ITO reduces Cash to Cash Cycle 库存周转创造现金流 ITO improves ROA 库存周转提高资产回报率 Earning … 赚钱 Healthy … 健康

  6. Plan Plan Plan Plan Plan Make Deliver Source Deliver Source Make Deliver Source Make Deliver Source Return Return Return Return Return Return Supplier Internal or External Customer Internal or External Return Return Customer’s Customer Suppliers’ Supplier Your Company Where is inventory? 库存在哪里？ Plan Inventory 计划库存 Transfer Inventory转移库存 Buy Inventory 采购库存 Make Inventory 制造库存 Transfer Inventory 转移库存 Transfer Inventory 转移库存 NORMAL inventory is the LINK of whole demand – supply chain … 正常的库存是需求与供应链管理链条的粘结剂 ABnormal inventory is the output of ABnormal processes or ABnormally executed processes … 非正常的库存是非正常的流程或者流程管理不协调的产物 Source – SCOR 7.0

  7. How to control inventory? 怎样控制库存？ Data Accuracy 库存数据准确性 suppliers - Delivery Accuracy – customers 供应商及时交货率 Delivery Flexibility 供应商交货灵活度 Forecast Accuracy / Variance 预测差异 Semi-FG/FG buffer % 成品、半成品库存 Full Kits Rate – R.M 原材料齐套率 JUST need to manage the processes … control points … 你只需要管理好流程 …控制点 …

  8. Why “MORE sales” could be “FASTER to bankrupt” ? 销售越大，企业倒闭越快？ Source – On source & analysis from Accenture Tsingtao Beer, Revenue increasing, EBIT/Net Income reducing … why?? 青啤产值急增，利润率急剧下降 … 为什么？ Too Much Inventory! Accenture said … 埃森哲说 …你库存太高！

  9. Why don’t we get the right parts on hand? （物料）为什么该来的不来，不该来的都来了？ The warehouse is FULL, but why I do not get the parts I need? 仓库里面爆满，但为什么我需要的物料就没有呢？ • Demand Fluctuation 需求波动 • Common vs Unique parts 公用－专用 • Over-production 过量生产 • Supply Flexibility 供应灵活度 • Data Accuracy 数据准确性

  10. Take all FOUR I need ONE! Over Production Why over-production is crime? 为什么说过量生产“罪大恶极”？ Line Stop Strategy … 停线策略 • Waste itself generates the other wastes! • 浪费本身产生浪费 • Over-production is NOT only FG/Semi-FG but generate more inventory on raw materials … • 过量生产所带来的不仅仅是成品、半成品库存，还有额外的原材料库存

  11. How are we organized ? – 3P - Process / People / Performance 我们的组织架构 － 3P管理 Planning计划 Customers Order Management 订单管理 Forecast / Order –MPS FG Hub / FG inventory on customers hand External Logistics 外部物流 Customs / Shipping Execution 执行 Procurement Commodity based / S-OTD Suppliers capacity management Suppliers inventory / Materials readiness Production Planning生产计划 Capacity / Scheduling Internal Logistics 内部物流 Warehousing / Replenishment Materials Planning 物料计划 MRP / Actions - PR Materials Project Management / SBM 物料项目管理 System readiness / Master data accuracy Materials Controlling 物料控制 MRB / Inventory data accuracy Suppliers Inventory Planning库存计划 ITO / E & O

  12. Case 1 – why did we lose this customer? 我们为什么丢掉客户？ • We “followed” the customer’s instruction strictly and stupidly … • 我们“机械”地按照客户的要求去做 • Too much buffer (Semi-FG) on hand – “agreement” • 合同里面“同意”了太多的“缓冲库存” • Invisibility on customer’s FG inventory • 看不到客户的库存 • Bureaucracy in both sides • 双方的官僚 • Huge liability for both sides • 巨大的物料责任

  13. Case 2 – why customer is respecting us? 客户为什么尊重我们？- 产品族相似性分析

  14. Case 2 – why customer is respecting us? 客户为什么尊重我们？ • Customer adjusted their forecast timely per our proposal • 客户按照我们的建议调整了预测 • We reduced the buffer – Semi-FG from 14 days to 2 days • 我们把缓冲库存又14天DOS降低到2天 • EOL quite smooth with little liability for both sides • 产品顺利结束生命周期，物料呆滞责任几乎为零

  15. EXXX (adapter product) – Product Life Cycle – is this the RIGHT MPS loading? 根据产品生命周期 – 这是正确的MPS吗？ E & O … Systematically generated shortage … 系统性物料短缺 … Very clear this product has weekly consumption around 50 ~ 60k and monthly around 200k … very stable …

  16. ERP vs Inventory … ERP与库存控制 Can inventory be surely reduced after implementing ERP? 上了ERP就“一定”能够降低库存吗？ For sure “it is NOT sure” ! 一定是不一定的！

  17. 谢谢各位! Thanks! 程晓华 著

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