supply chain

Two basic functions:

Physically converting raw materials and
components into products and delivering
them to the end customers. Related to
physical costs (Sourcing, Production,
Distribution, Warehousing, Inventory
Control)
Make sure that products/services delivered
satisfy customers aspiration. Related to
market mediation costs (Marketing
Research, Product Design, Demand
Management, After Sales Service)
Aspek Fungsional Inovatif
Siklus hidup > 2 tahun 3 bulan -1th
Variasi 10 20 variasi Banyak, ribuan
Volume tinggi rendah
Peramalan
permintaan
Relatif mudah,
akurasi tinggi
sulit, kesalahan
tinggi
stockout rate Hanya 1% - 2% 10% - 40%
Kelebihan
persediaan
Jarang Sering terjadi
markdown Mendekati 0% 10 25%
Marjin rendah tinggi
Keputusan
taktis
Efisien Responsif
Lokasi
fasilitas
Tempatkan
pabrik di
negara murah.
dekat pasar,
akses tenaga
terampil
teknologi
memadai
Sist prod Tingkat utilitas
sistem
produksi harus
tinggi
Sistem produksi
harus fleksibel
dan ada
kapasitas ekstra
Persediaan Perlu upaya
meminimasi
tingkat
persediaan
Diperlukan
persediaan
pengaman yang
cukup di lokasi
yang tepat
Transport Pengiriman TL /
CL atau
subkontakkan
ke pihak ketiga
Perlu
transportasi
cepat. perlu
tetapkan
kebijakan LTL/LCL
Pasokan Pilih supplier
dengan harga
dan kualitas
sebagai kriteria
utama
Pilih supplier
berdasarkan
kecepatan,
fleksibilitas, dan
kualitas
Peng prod Fokus ke
minimasi
ongkos
Gunakan
modular design
dan
(postponement)
postponement
manufacturing postponement is to retain the
product in a neutral and non-committed
status as long as possible in the
manufacturing process. This means to
postpone differentiation of form and identity
to the latest possible point
To support mass customization
Large product variety with uncertain mix
Many common components / sub-
assemblies
Relatively short lead time for final
configuration (compared to waiting time
tolerated by customers)
Stages often postponed: final assembly,
packing, labeling, color mixing, etc.


inventory
Based on their status: Raw materials, Work in
process (WIP), finished goods
Based on their functions: Pipeline / in-transit
inventory, Cycle stock, Safety stock,
Anticipation stock
Inventory Turnover rate: Measures how
many times or how fast inventory is turn to
the customers relative to those kept in the
warehouse. Perhitungannya bisa didekati
dengan rumus berikut:
Turnover ratio = nilai penjualan dalam
setahun/nilai persediaan
Semakin tinggi nilai turnover ratio semakin
bagus bagi perusahaan
Inventory days of supply: Jumlah hari yang
bisa dicover oleh rata-rata inventory.
Dipengaruhi oleh lead time pengadaan, pola
permintaan, harga, dan ketidakpastian supply.
Inventory days of supply bisa dihitung per
item atau diaggregasikan untuk semua item.
Perhitungan IDS = Rata-rata nilai
inventory/Rata-rata pemakaian per hari
Model Pemesanan EOQ
Total cost = Order cost + holding cost

D = annual demand
Co = order cost
h = inventory holding cost
Reorder point menunjukkan posisi persediaan
dimana pemesanan perlu dilakukan. Biasanya
menunjukkan rata-rata kebutuhan selama
lead time.
Apabila lead time adalah l periode dan
kebutuhan per periode adalah d maka pada
situasi l dan d deterministik, ROP = l x d.
Akurasi catatan persediaan
Bisa dihitung dengan mencari persentase
catatan yang sama dengan jumlah fisiknya.
Salah satu cara untuk menaksir akurasi
catatan persediaan adalah dengan Cycle
counting. Cycle counting disebut juga sebagai
stock opname atau physical counting. Intinya
adalah melakukan pencocokan antara berapa
yang ada di catatan dengan berapa yang ada
di gudang.
Misalkan dari 1000 barang yang disampel
ternyata 150 diantaranya ada deviasi antara
catatan dan jumlah fisik maka akurasi catatan
inventory adalah 850/1000 x 100% = 85%.
bullwhip effect
Merupakan suatu fenomena meningkatnya
variabilitas order / permintaan ke arah hulu
pada supply chain. Artinya, semakin ke hulu,
variabilitas semakin tinggi. Permintaan yang
mungkin agak stabil di hilir berubah menjadi
lebih fluktuatif di hulu karena berbagai sebab.
Pada awalnya fenomena ini diidentifikasikan
terjadi pada produk-produk P & G, dimana
kebutuhan Pampers Diapers yang stabil di hilir
berubah menjadi fluktuatif di hulu.
Penyebab:
Setiap pemain menggunakan informasi yang
berbeda dan memprediksi kebutuhan secara
terpisah
Adanya waktu sela (lead time) dalam
menyampaikan informasi maupun dalam
memproduksi dan mengirim barang
Pembelian / produksi yang mengharuskan
jumlah minimum tertentu
Fluktuasi harga atau adanya potongan harga
pada saat-saat tertentu yang mengakibatkan
permintaan naik secara signifikan pada
periode-periode tersebut.
Rationing and shortage game. Ini adalah
fenomena dimana kalau total pasokan lebih
kecil dari total kebutuhan maka perusahaan
hanya akan memenuhi sebagian kebutuhan
pelanggan. Akibatnya, pelanggan cenderung
memesan lebih banyak dari kebutuhan
mereka.
Akibat:
Terjadi penumpukan inventory di saat-saat
tertentu, tetapi bisa mengalami kekurangan di
saat-saat lain. Akibatnya, kepuasan pelanggan
berkurang.
Efisiensi operasional menjadi rendah,
dikarenakan terjadi pemakaian kapasitas yang
terlalu sedikit pada saat-saat tertentu dan
kekurangan kapasitas di saat-saat lain.
Kebutuhan modal kerja akan fluktuatif
mengikuti ritme produksi.
Banyak frustrasi dan saling menyalahkan.
Cara mengurangi:
Information sharing (membagi informasi)
antar pemain sehingga masing-masing bisa
lebih transparan dan mengetahui apa yang
terjadi di pihak lain pada supply chain.
Channel alignment, misalnya dalam bentuk
mengurangi pemain antara pada supply chain.
Contohnya, memangkas jaringan distribusi
seperti yang dilakukan Dell Computers.
Operational efficiency, misalnya dengan
memperpendek lead time pengadaan.
product design and the supply chain
why do good design matters?
Expenses related to design account for
about 5 15 percent of product cost;
70% of delivery cost results from design.
Results of poor design;
Product appearance is not appealing;
Product price is too high;
Late product introduction;
Spectrum of Approaches to Design
Traditional over-the-wall design: supplier
plays no role in design
Informal collaboration: includes
information from conversations or informal
consultation with suppliers
Formal collaboration: involves
representatives of the suppliers in a formal
collaboration
Supplier design: the supplier designs the
product based on general specification from
the buyer.
Prinsip Design for Manufacturability
Simplify the design to minimize number and
variety of parts and the number of times
components are handled and inserted.
Standardize materials and components
across product families and use off-the
shelf parts whenever possible.
Aim for modular design and product variety
introduced at the latest possible stage of
production.
Make the best use of available production
processes to achieve simplicity
Develop teams that include representative
of all relevant disciplines and departments
Memperpendek time to market
Keterlibatan banyak pihak mulai dari wakil-
wakil bagian (fungsional) di dalam
perusahaan maupun pihak luar seperti
supplier dan pelanggan (concurrent
engineering)
Manajemen proyek yang bagus
Tim perancangan produk yang solid,
dinamis, dan enerjik, serta
Teknologi yang mendukung.
Prinsip Design for Logistics
Include logistics specialists whose role is to
view the design with an eye toward creating a
product that can be economically packaged,
stored, and transported.

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Design for Reverse Logistic/Environment
Easy to return, repair, replacement
Provision of reuse or recycling
Avoidance of hazardous materials or
mitigated danger
Reduced energy consumption
Use of lighter components and less
materials
Modular Design
A module is a part that can be used in
multiple products.
Modular design is the planning of products
with consideration for using existing
components rather than starting from
nothing. It also means consciously designing
new products so that their components can
be shared with existing or future products
(It is a type of component commonality).
Opposity of modularity is integral design
(all components are designed to work
together in one specific product).
Mass Customization
Using the concept of postponement
Aim to produce high product variety with a
large percentage of common materials
Benefits: economies of scale, reduced
inventory, customization.
Drawbacks: cost of investing in equipments
and training of distributors to assemble the
products.
Component Commonality
Similarity in the components needed to
produce products.
It can reduce the complexity of the
manufacturing system
It can reduce the need for safety stock
because of the pooling effect (reduced
uncertainty)
Quantifying Impact of Component
Commonality
Component commonality can reduce safety
stock
If two different components are
standardized, the level of uncertainty
decreases, thus the total safety stock
needed decreases (assuming that the
demand of the two components is
independent)
Standardizing expensive components has
more impact on cost savings, also for
components with higher demand
uncertainty
Example
Currently you have 4 components each with a
weekly demand normally distributed N(800,
100). Assume that production lead time is 1
week. The target service level is 95% for each
component. Calculate the safety stock needed
for each component and for all four
component.
If all those components are standardized into
one, what would be the safety stock level
needed?
Solution
SS = Z(95) * Sdl = 1.645 * 100 = 164.5 units
Thus, the total of safety stock for 4 items
would be 4 * 164.5 = 658 units.
If all four components are standardized then
the safety stock requirement is 1.645 * 100 *
SQRT (4) = 329 units