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1. Stephen P. Crane, CSCP
Wacker Chemical Corporation
Director Strategic Supply Chain
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Page 3 WE ARE COMMITTED TO BENCHMARK-QUALITY PRODUCTS DESIGNED FOR OUR FOCUS INDUSTRIES
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Page 4 CONTENT
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Page 5 WHAT IS SALES & OPERATIONS PLANNING? Is an executive decision-making process
Ties operational plans to financial plans: ONE set of numbers
Is a forum for setting relevant strategy and policy
Balances demand and supply
Deals with volume in both units and $
Monthly process reviewed by management at an aggregate level
What business plans to do covering an 18-month horizon to:
Plan for resources
Execute business plan/strategy
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Page 12 CONTENT
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Page 13 TYPICAL BENEFITS FROM IMPLEMENTING S&OP Forecast error reduction……20-25%
Inventory reduction………...…5-10%
Inventory turns increase….….5-10%
Service level increase…… ...5-10%
Top Line revenue growth.…..…2-5%
SKU rationalization……….…10-20%
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Page 14 HIGH FORECASTING ACCURACY YIELDS TANGIBLE BENEFITS IN SUPPLY CHAIN PERFORMANCE High forecast accuracy cuts cost out of the entire supply chain
Companies that are best at demand forecasting average;
15% less inventory
17% higher perfect order fulfillment
35% shorter cash-to-cash cycle times
1/10 the stockouts of their peers
1% point improvement in forecast accuracy can yield a 2% point improvement in perfect order fulfillment
3% increase in forecast accuracy increases profit margin 2%
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Page 15 Companies with higher forecast accuracy also achieve better delivery performance
Delivery performance to request date increased 2% for each 5% increase in forecast accuracy
BENEFITS OF IMPROVING FORECAST ACCURACY
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Page 16 INVENTORY LEVEL VS. FORECAST ACCURACY
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Page 17 BENCHMARKING OBSERVATIONS Emphasize S&OP as a first step
S&OP is the most critical element to drive supply chain benefits
Demand planning and supply planning are the largest profit drivers
Supply chain benefits normally fall into the range of 3 to 5% of sales revenue on a sustainable basis through CI efforts
Over 50% of increases in shareholder value over the past three years have come from supply chain improvements
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Page 18 CONTENT
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Page 19 AIR PRODUCTS POLYMERS BUSINESS UNIT $600 million global business
Diversified geographies
65% of sales in N. America
30% Europe, 5% Asia
6 Plants (4 NA, 1 Europe, 1 Asia)
600 Products
1,800 Ship-to Customer Locations
3,500 Planning Combinations (Material-Ship-to-Primary Source Plant)
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Page 20 Just went live on SAP, master data issues
New processes, tools, and data sources
Planning processes loosely integrated
Poor visibility of demand/supply balance
Numerous service issues, late deliveries, renegotiated orders
Communication gaps between business, finance, and supply chain
No linkage between volume forecasts for supply chain and financial forecast WHERE THEY STARTED IN 2003
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Page 21 GLOBAL WORK PROCESSES
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Page 22 S&OP PROCESS STEPS
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Page 23 S&OP PROCESS CYCLE
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Page 24 EXECUTIVE S&OP MEETING
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Page 25 S&OP DRIVES THE BUSINESS PLAN
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Page 26 S&OP PROCESS KPIs Forecast Accuracy (%)
Production Plan Adherence (%)
Inventory Days of Supply
Financial Forecast Accuracy (%)
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Page 27 Major sources for forecast inaccuracy:
Upside account assumptions
Consignment billing issues
Price increases
Raw material supply allocations
APO master data
Major sources for forecast inaccuracy:
Upside account assumptions
Consignment billing issues
Price increases
Raw material supply allocations
APO master data
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Page 31 WHERE ARE THEY TODAY Improved visibility of demand and supply
Improved service, On-Time Delivery at 98%
Improved financial forecast accuracy
S&OP meetings are boring…a sign of success
Communications aligned between business, finance, and supply chain
Sales and volume forecasting for outlooks/budgets; easier and more accurate; drives supply chain plans
Business plans validated against supply chain capabilities on a monthly basis
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Page 32 One volume forecast aligned w/ all business plans; Financial, Supply Chain, Operational, & Commercial
Ongoing net productivity benefits ~ $18 Million+ / year
Improved financial performance
Net Asset Investment down by 25%
Operating Income increased by 80%
ORONA improved from 5% to 13%
MAJOR IMPROVEMENTS SINCE 2003
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Page 33 THE S&OP CHECK LIST If you answer no to any of these questions, you have an opportunity to go back and make improvements to your current S&OP process.
Hopefully you have heard a few key points this afternoon that you can take back to your company and apply to your S&OP process.
Thank you.If you answer no to any of these questions, you have an opportunity to go back and make improvements to your current S&OP process.
Hopefully you have heard a few key points this afternoon that you can take back to your company and apply to your S&OP process.
Thank you.
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Page 34 ROAD BLOCKS & CHALLENGES
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Page 35 BU A FORECAST DEVIATION TREND It took only 6 months to achieve the lowest Forecast Deviation in Wacker
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Page 36 BU B FORECAST DEVIATION TREND Forecast deviation chemical product level
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Page 37 “The only sustainable competitive advantage any company can have is the ability to consistently react to market opportunities faster than the competition. A company’s products, engineering, proprietary manufacturing processes or even a powerful brand simply no longer ensure long term, sustainable advantage”
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Page 38 The WACKER Group