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Some examples
of successful
restructuring experiences
Table of contents
What is Tacis?
Foreword
11
14
Lessons learnt
17
22
28
35
Table of contents
39
46
53
60
Questionnaire
61
Acknowledgements
We wish to thank the participation in the preparation of this brochure of:
the Ukrainian Centre for Post Privatisation support in Kiev, and in particular its director, Mr Savruk Olexander
the Russian Privatisation Centre in Moscow, its managers and Mr Jean Marie Roche
the members of the consulting team of the Tacis project Post privatisation support in Ukraine
Mrs Annie Cordet-Dupouy.
What is Tacis?
The Tacis Programme is a European Union initiative for the New Independent States and
Mongolia which fosters the development of harmonious and prosperous economic and
political links between the European Union and these partner countries. Its aim is to sup
port the partner countries' initiatives to develop societies based on political freedom and
economic prosperity.
Tacis does this by providing grant finance for know-how to support the process of trans
formation to market economies and democratic societies.
In its first five years of operation, 1991-1995, Tacis has committed ECU 2,268 million to
launch more than 2,200 projects.
Tacis works closely with the partner countries to determine how funds should be spent.
This ensures that Tacis funding is relevant to each country's own reform policies and pri
orities. A part of broader international effort, Tacis also works closely with other donors
and international organisations.
Tacis provides know-how from a wide range of public and private organisations which
allows experience of market economies and democracies to be combined with local
knowledge and skills. This know-how is delivered by providing policy advice, consultancy
teams, studies and training, by developing and reforming legal and regulatory frame
works, institutions and organisations, and by setting up partnerships, networks, twinnings and pilot projects. Tacis is also a catalyst, unlocking funds from major lenders by
providing pre-investment and feasibility studies.
Tacis promotes understanding and appreciation of democracy and a market-oriented
social and economic system by cultivating links and lasting relationships between organ
isations in the partner countries and their counterparts in the European Union.
The main priorities for Tacis funding are public administration reform, restructuring of
state enterprises and private sector development, transport and telecommunications
infrastructures, energy, nuclear safety and environment, building an effective food pro
duction, processing and distribution systems, developing social services and education.
Each country then chooses the priority sectors depending on its needs.
Tacis w o r k s with 13 partner countries (12 NIS and Mongolia):
Armenia
Azerbaijan
Belarus
Georgia
Kazakhstan
Kyrgyzstan
Moldova
Mongolia
Russian Federation
Tajikistan
Turkmenistan
Ukraine
Uzbekistan
Foreword
Since 1991, useful work, in a variety of different forms, has been done to assist partner
countries through the Tacis programme. In particular, practical field work, with more visi
ble benefits, has been conducted on a more systematic basis since 1993.
A number of projects were successful in developing and testing possible solutions to
help partner countries adjust to a market economy. The impact of these projects is not
limited to the narrow geographical area in which they were implemented. Results will also
benefit organisations and individuals in other regions.
The above is the main aim of the Tacis technical dissemination project (TDP). TDP
selects projects with results that are worth disseminating, and develops material to facili
tate the replication of those useful results. The content of this document is one such
action.
TDP produces and disseminates various types of material
documentation on comprehensive actions successful in facilitating adjustment to a
market economy
tools to help individuals or organisations understand how they perform, and therefore
better enable them to adjust
training materials to facilitate quicker adjustment as part of the process of change.
Documents edited by TDP are not coloured by a particular ideology or political doctrine,
and they do not intend to prescribe any one solution to a problem. What is reflected are
merely the results achieved in a given situation, and the details of tools used to good
effect by local people in adjusting to their changing environment.
Replication of these results is possible, provided readers make an effort to adapt the
contents to their local environment. Situations can be similar, but are seldom Identical.
This brochure was developed on the basis of the experience and results achieved by the
project described hereafter.
Tacis would be happy to receive suggestions and comments on this document. Please complete the question
naire at the end of the document and return it to a TDP distributor (see addresses on page 60).
Macro-economic
reforms
Economic
recovery
Enterprise
restructuring
Former State enterprises, even when privatised, are resilient to changes; they can hold
the reform process and the State budget hostage. Privatisation programmes have some
how progressed (at a slower pace in Ukraine than in Russia), but the strategy for owner
ship reforms, and restructuring of enterprises has still to be defined. Restructuring of
privatised enterprises has proved very difficult, especially when the ownership had been
transferred to managers and employees.
There is a general agreement that enterprises cannot survive without restructuring. But
how to implement It with success is very difficult. Furthermore, the business environment
(taxes, laws and in particular bankruptcy laws, labour markets, trade barriers, etc.) is not
yet positive, and does not provide incentives for restructuring. However, the depth of the
economic crisis (the industrial production has continued to shrink in 1996 and in early
1997 in both countries) is the driving force behind restructuring, even if the business
environment is not always positive. Most enterprises have seen their sales drop by a fac
tor of 50 or more per cent if compared to 1990, and they understand that they cannot
rely anymore on the State to save them. Many enterprise managers have dreamed of the
white knight foreign investor, bringing money, but not interfering in the management.
With time, hopes have faded, and managers and shareholders are now realistic. They
recognise that they have to create their own future, and restructuring of their enterprise is
going to be one of the first steps in this direction. This handbook aims at sharing the
experience of a few companies which have started restructuring, and at identifying a few
restructuring solutions which have proved workable in the Ukrainian and Russian con
texts, and therefore can be applied to other enterprises.
Restructuring is not unique to Russia and Ukraine, and many western enterprises have
been faced with similar (although sometimes less acute) problems especially in periods of
deep market changes. The specificity of Russia and Ukraine is that most enterprises are
in need of restructuring at the same time as the drastic change in environment has
affected all enterprises. In Europe, for example, after the oil crisis of the seventies, most
energy intensive industries (e.g. cement, chemical industries, metal industries to name
but a few) were deeply affected while others were unaffected. In the US, following the
agricultural crisis of the seventies/early eighties, many agricultural machinery producers
were in deep trouble, without market. A famous case is the International Harvester where
several restructuring were attempted without success (the collapse of the agricultural
machine market was not recognised and optimistic management thought the market
would recover the following year while it continued to decrease for several years); their
competitors took harsh measures and survived, while the famous International Harvester
brand disappeared from the market. Another business schools classic case is the watch
industry in Switzerland which was collapsing due to change of technology (cheap elec
tronic movements versus expensive mechanical ones) and competition from new pro
ducers in the Far East. It was drastically restructured and revived thanks to a
combination of the launch of new products (the famous SWATCH), focus on design and
marketing for the higher end of the market, overall decrease of costs; and strong focus
on branding.
There are many ways to approach restructuring. It may encompass many aspects which
can be addressed in parallel or phased depending on the situation of the enterprise, the
sector and the economic environment.
Restructuring may be costly and requiring new investments for modernisation, cost
decrease and launch of new products. But certain phases of restructuring can be imple
mented rapidly1 using the only internal resources of the enterprises.
Restructuring is not continuously complaining about the current situation and hoping that
God or somebody in the Centre will improve the situation. It is an active recognition of the
problems faced by the enterprise, and a hands-on tackling of the necessary changes by
the shareholders and the management team of the enterprise.
In the NIS context, once the diagnosis is completed, and that the enterprise strategy and
the restructuring plan are agreed with the management and the shareholders, implemen
tation of restructuring can be conceived around two main phases (see Figure 2):
a first phase, articulated on urgent measures, alms at improving the overall situation of
the enterprise, improving the skills and the morale of the staff as well as the perception
of the enterprise by outsiders. Through this phase, the enterprise improves its opera
tions, and very Important, secures Its credibility towards outside financiers, thus
increasing its chances to secure the necessary funding for new projects aiming at
bringing new technologies, increasing production or reducing costs; all projects which
are part of the second phase of restructuring. This phase generally requires low
investment
a second phase builds on the improvements achieved during the first phase. It
secures the future of the enterprise through the implementation of more ambitious
projects requiring significant financing.
First phase
Financial restructuring
Investment in new equipment
Investment in human resources
Later on
Ownership restructuring
It usually addresses key weaknesses of former soviet enterprises entering the market
economy, namely market and sales, finance, organisation, etc.
Organisational and managerial issues
The organisational and managerial issues Include the identification of the enterprise's
core and optimal activities and markets, the analysis of weaknesses in all functions of the
enterprise and the preparation of concrete proposals of remedies (at low cost and
through redeployment of internal resources of the enterprise).
For example, actions on the following can bring very rapid visible results:
management of cash flow
cost reduction through identification of exaggerated high costs items and material
losses
establishment of a sales force
redirection of product mix, concentrating on core business for too diversified enter
prises, but more often widening the range of products offered as the former all-union
enterprises which were part of a wider group of plants were producing a very narrow
range of products, complemented by the production of other plants, today in other
countries
lay-off of some of the redundant labour (while labour is still cheap in former soviet
republic, it has nevertheless an important impact in certain industries. Moreover, it has
an impact on the quality, and on the overall morale of the staff).
Physical/assets restructuring and operational changes
Very often enterprises are affected by a poor lay-out of the plant and by rigidities in pro
duction due to the tradition of long production batches.
Actions on the following will bring again visible results within a one year period:
improvement to the lay-out of the plant (See Figure 3)
spin-offs and disposal of non-operational assets (social assets, maintenance assets,...)
modification of operations so as to decrease the standard time to change tools/ pro
duction
initiation of a quality control process (the introduction of a full quality control process
will require a much longer time).
10
Before restructuring
Production workshop of rough shaped rollers before restructuring
After r e s t r u c t u r i n g
Production workshop of rough shaped rollers after restructuring
Tool storage
Cold stamping
machine dedicated
according to wire
diameters
Spool holders
carousels
Strainer
Tool storage
Cold stamping
machine dedicated
according to wire
diameters
Container for collecting
semifinished spools
The second phase of restructuring addresses other aspects which may be initiated.
on t h e i m p r o v e m e n t s
financial restructuring
a c h i e v e d duri ng t h e fi rst
p h a s e . It c o n s i d e r s m o r e
ambitious projects
requiring si gni fi cant
financing.
It is a necessary measure for enterprises overloaded with debts. However, creditors will
not accept to initiate it in the absence of a credible plan for overall restructuring and
recovery.
investments in new equipment
These investments may be financed through a variety of financial sources such as loans
(but often difficult to obtain If the financial situation of the enterprise is poor), or investors
(new share issues to existing shareholders, strategic Investors to bring both financial and
business skills, and financial Investors). The Investment activity may also cover invest
ments to obtain the certification for new standards.
investments in human resources
Investments in human resources are necessary, especially in the sales/marketing and
finance areas (e.g. recruitment of a top salesman or a finance manager).
ownership restructuring
Ownership restructuring has been little seen so far in Russia and Ukraine, but it will pro
bably become very Important In the future given the ownership structure resulting from
privatisation in both countries. This may cover mergers with enterprises having comple
mentary productions and markets, spin-off of unrelated activities, concentration of share
holders through various means.
11
The manager and his team, as well as the enterprise shareholders have first to recognise
that their enterprise is facing a new challenge (e.g. current or forthcoming competition,
technological changes, loss of major markets) or that they have identified symptoms of
illness (financial troubles for example) that they do not know how to solve without exter
nal assistance in a short period of time.
Problems vary with the type of industry (for example manufacturing, consumer goods
products, process industries, etc.), the economic and social environment, the country as
each of the former soviet republic has evolved differently since independence. But inher
itance from the past soviet system indicates a few recurrent syndromes identified in
many enterprises. Managers or shareholders must be convinced that they are not alone
with the problems they are facing in their company.
Most of the time, in those enterprises that need to be restructured, some if not all of the
following features can be found:
there is no proper marketing/sales department, and the enterprise has difficulties to
understand who the client is and what he wants
the financial strategy is non existent
the enterprise lacks working capital and the absence of liquidity is blocking the re
covery of enterprise
in the daily life of the enterprise, the manager decides on everything and does not del
egate
the poor quality of products and no quality control process are hampering the cost of
products (very high reject rate) and the image and saleabillty of products
the product design (especially for consumer products) is not matching the require
ments of clients
The manager and the shareholders of an enterprise in need of some sort of restructuring, may recognise them
selves in some of the following statements and questions:
- Yes, we know how to make product X, Y, Z, but our sales are dwindling and our financial situation is dreadful;
the salaries have not been paid for months; we have a huge debt to the budget
- Why do we make these products today? Why are the customers willing (or not willing) to buy products , ,
from our factory? Where are our clients; and at which price they are willing to buy from us?
- Where can I get raw materials at best price?
- Why do we have so many rejects to achieve not even a good quality?
- We do a lot of barter, but what is the financial result from this barter?
- Investment is the only way to restructure the company.
12
the management attitude (risk averse and lack of strategy) is inherited from the past
the costing methodology prevents the enterprise from understanding the origin of high
costs and to compete on the market
the burden of social costs is impacting the results of the enterprise
the enterprise is undercapitalised and the shareholders cannot bring fresh money.
The manager and his team and/or the shareholders have then to find an approach to
design and implement the necessary restructuring. The assistance of consultants (local
or foreign) may help accelerating the restructuring process, and this may be critical in
certain cases when the enterprise competitive position is deteriorating. The consultants
will act as catalysts, and will stimulate the recovery process of the enterprise. It is how
ever crucial at this stage that any misunderstanding be eliminated so as to ensure
smooth working conditions for the restructuring effort.
To maximise the advices provided by the consultants, the manager has to allocate one
or several professionals to work with the consultants so as to help them to make the
diagnosis as quickly as possible. The professionals will also gain an immense experience
and they will later disseminate their know-how to their colleagues. They will be the pivotal
team of the enterprise to implement restructuring.
What should the management expect from external assistance?
The consultants can help greatly in the elaboration of the diagnosis and in recom
mending measures to be implemented to improve the situation, as well as coaching
during the implementation phase. Their knowledge of similar plants and enterprises in
the West and in NIS enable them to diagnose the main issues very rapidly, and to
explain what should be done to rectify the problems, why, and what kind of results
could be expected.
They will help benchmarking the enterprise vis--vis its competitors. But in the most
important phase, the implementation, the staff of the enterprise should be In the fore
front, with the constant support of the consultants' team.
The consultants will bring support and vision to the internal task force. The consul
tants can help organise the effort, coach and train people, but the ultimate respon
sibility lies with the management of the enterprise, and with the shareholders If
some of the problems have their roots within the management team.
The consultants can help the enterprise preparing for a partnership (financial partners,
commercial partners), help Identify potential partners, and prepare the management
for the negotiation covering a long list of complex Issues, and advising the manage
ment on how to deal with them.
But external assistance cannot solve all problems. Consultants do not know the enter
prise better than its managers. Their role is summarised in Table 1.
A consultant can:
elaborate a diagnosis and recommend
measures to improve the situation
help benchmarking the enterprise
vis--vis its competitors
bring support and vision to
the internal task force
help the enterprise preparing
for a partnership
13
14
Company
Country/Sector
Period of
assistance by
consultants
Efremov
Russia/Rubber
Lustsk Ball
bearings
Ukraine/
Mechanical
industry
Gavrilov
Russia/Textile
Main problems
see below notes 1/ and 2/
Proposed restructuring
strategy
be one of the top key players
on the European market
of polybutadlene
Main results
certification with all main
tire producers in the west
side products have been dropped
recovery with profit in
1995 and 1996
good short term finance
equity investment by EBRD of
$38 million agreed in fall 1997
increase of sales for the first
6 months of '97 (plus 47%
if compared to first
6 months of '96)
new flexible lay-out of the plant
enlarged range of products
significant increase in sales,
both globally and per employee
development of new products
development of sales network
in Russia and of international
contacts (participation to the
Frankfurt fair)
negotiation under way for
a new investment (in joint-venture)
for the production of high count
linen (about $6 million)
Ui
c
Period of
assistance by
consultants
Main problems
Proposed restructuring
strategy
Main results
Company
Country/Sector
Kiev Sanitary
Equipment
Ukraine/
Construction
materials
- outdated technology
- no commercial/
marketing team
- cash-flow difficulties
- one customer represented
the major part of the sales
(90% In 1995)
Carpaten
Ukraine/
Furniture
- company technically
bankrupt, with bank
accounts blocked
- terrible quality/ design of
products
- no commercial/ marketing
team
- poor lay-out of the plant
Akrlkhin
Russia/
Pharmaceuticals
- Increased sales
- focused product portfolio
- cost reduction and improved
competitiveness
1 / drop of sales has not been mentioned as it affected more or less all companies during the early period of the break-up of the former Soviet Union; similarly, even when not mentioned, the lack of
marketing and sales net-work is common to all companies.
2/ non existent cost accounting was a problem in all enterprises.
17
Lessons learnt
Business managers and shareholders are key factors of change in NIS countries. The
work with enterprises and the success of restructuring would extend beyond the indi
vidual cases and the initial results which have been achieved, and are reported in this
handbook. It is evident that there is a burgeoning demand for restructuring, or more
precisely for Improving the situation of enterprises which are faced with unprecedented
problems.
Enterprise restructuring
in NIS countries is
addressing rigidities
A review of the above cases provides evidence of the impact and efficiency of restructur
ing, and also information on how it has been designed, implemented, and what are the
early signs of recovery.
Once managers and shareholders have agreed that they want a restructuring, that they
are ready to allocate resources to ensure its success, the real work can start.
The first step is to carry out a SWOT analysis' (Strengths, Weaknesses, Opportunities
and Threats) or similar analytical grid to collect Information on sales, finance, produc
tion, personnel. This analysis is always supplemented by minute plant visits, face-toface interviews and observations. Sometimes, the diagnosis is very quick, sometimes
it takes a longer time if the company is important, active in many businesses, has sev
eral production sites, etc.
Recommendations will rapidly be formulated and in particular short term measures to
be implemented immediately. For example cash stabilisation programmes have been
implemented in Efremov (synthetic rubber) in Russia as well as in Carpaten (furniture)
in Ukraine.
Short term actions on sales and market, finance, product design, quality, housekeep
ing, cost control, show results very rapidly.
New products developments, new markets, changes of strategy may require more
time to be fully prepared, and also to be financed, but in a number of the above cases,
in particular in light industries (textile, furniture, light mechanical industry), companies
have been able to introduce new/improved products within a year.
The search for a partner is a longer term goal, as negotiation may take some time, and
in many cases may be initiated only when the enterprise has regained a certain look.
A very simple act of change is housekeeping. So many plants are full of pieces of
metal, wood or junk; everything is rusting; nothing is clean. This can be changed
almost overnight, and it will immensely improve the morale of workers.
An analysis of the examples provided in this brochure shows that it takes time to find real
financial investors. For example, in the case of Efremov, the synthetic rubber company,
the discussion with the EBRD started during the project, late '95, and the final agreement
has only been signed in fall '97. Agreements with commercial partners are quicker (not
necessarily easier), and examples both in Russia (Gavrilov) and in Ukraine (Kiev Sanitary
Equipment) demonstrate that they are feasible within a couple of months.
The need of sequencing is critical in the case of NIS enterprises as they cannot generate
quickly funding through the disposal of assets or shares as their western colleagues do.
Announcements of sales of assets or divisions or subsidiaries are found every day in
newspapers like the Financial Time or the Wall Street Journal, but such moves are diffi
cult in Russia and Ukraine. But Russian or Ukrainian enterprises have shown that they
have significant possibilities of productivity improvements and cost savings.
18
Lessons learnt
Restructuring implies a major change in the enterprise. This change has been and is still
stressful, and it appeared that resistance to changes is building during the restructuring
process. Even when the manager and the shareholders were willing and asking for
restructuring, they have been faced with difficult decisions requiring sometimes an indepth change of attitude. This has required a lot of communication and information from
the consultants at all levels. In cases not reported In this brochure where the communi
cation had failed, the restructuring process has aborted. Not only the consultants have to
explain the whole process and explain it again to everybody', but the managers and the
shareholders have to communicate and explain their strategy to the workers to ensure
that they will support the effort, and not sabotage It. Through discussions with the con
sultants, visits to western plants and exchanges with western managers, very often the
management team has rapidly understood the necessity of the actions proposed by the
consultants, and their long term implications for the enterprise. Their European col
leagues have often explained that they also had to go through restructuring, even if
necessity is generally less drastic than in Russia or Ukraine. The Russian or Ukrainian
managers have gained confidence In the proposed restructuring process, and were able
to share this confidence In the future with their colleagues and the workers. Some of the
cases highlighted above have gone through such an internal crisis, but all have suc
ceeded to overcome It through dialogue and communication.
Restructuring threatens the status-quo as it requires changes from everybody. There is
therefore a need for a very deep co-operation between the various actors to lessen ten
sions, and avoid misunderstandings. Explanations are needed not only at the level of the
management, but also at the level of workers, for example to explain the background to
changes in the production organisation to Improve productivity, to introduce a continu
ous quality control process which is not an ex-post reject of defective products. Also, as
in most enterprises of the region, there is redundant labour, and lay-off plans, when
necessary the restructuring process will have to be discussed with not only the workers,
but the local community (municipality, region). This is also particularly true when the
enterprise needs to get rid of social assets and services and to transfer them to the com
munity.
Restructuring Issues can be exacerbated by certain forms of privatisation when man
agers and workers own a large part of the enterprise, and this is the case in many enter
prises in Russia and Ukraine. The decision process is difficult, and through these
privatisations, general manager have gained power. The workers cannot say much
(despite their status of shareholders), and there is no more counterbalance from a power
in the Centre. The chances of success of restructuring these types of enterprises lies
mostly with the manager, who needs to have the intelligence to see that through this dif
ficult process by which his power may be decreased, the future of the enterprise (and
de-facto the future earnings of the manager) may be greatly Improved. Also the workers
have to understand that even if they are no more part of the enterprise, the benefit from
restructuring will bring them dividends in the future (the case of Lustk bearings is very
illustrative of the dialogue with the workers to decrease the personel).
As said above, the key to a successful restructuring is motivation for changes, and set
ting-up joint task-forces between the outside advisers and the enterprise staff. This has
been a constant feature jn all the cases presented In this handbook.
Lessons learnt
19
It is difficult to identify criteria to measure success in advance, but in the long term, finan
cial sustainabllity and improved profitability are certainly one criteria or THE criteria.
However deterioration of the overall financial situation may appear during restructuring
due to the cost of certain measures (e.g. severance payments to redundant personnel,
new investments, etc.) as it is the case during most restructuring everywhere. For exam
ple, as quoted in a European financial newspaper: the operational profit of company X
shows a 60% Increased profit for the first 6 months of 1997, while the results are still
negative due to restructuring costs. Prospects for 1997 are excellent
Early signs of recovery include increase of sales, in particular sales of new products,
decrease of production costs, decrease of barter and receivable, Increase of cash flow to
name a few. The cases presented in this handbook all show most of these positive indi
cators of success, which will enable the enterprises to build on their first effort. The value
of shares is not yet an indicator in Russia and Ukraine given the lack of liquidity and
transparency of the capital market. But it will certainly be an indicator in the future as it is
in most western countries. Most companies with successful restructuring experience a
significant increase in their share price. This is very important for the company which will
need to tap the financial markets to finance development and new investments.
A very important aspect (although difficult to measure) gained through the restructuring
process is the adaptation to the reality and change of attitude. Several cases describe
companies where managers were frustrated, and the morale very low (the worst case
was probably Carpaten in Ukraine). At the end of the process (in fact, it is a progressive
change), the management team took risks, reacting to the market and the financial situa
tion; the manager got feedback from the various members of his team. The sales man
ager (which did not exist as such before) got feedback from the customers who are
happy or not happy with the quality, the quantity, the design. In other words, the man
agement team and sometimes the workers have moved from a passive attitude to an
active one.
In all cases, one of the early diagnosis has been the lack of sales and marketing staff.
Given the rigidity of the labour market where it is difficult to find good salesmen (the few
specialists are quickly taken by joint ventures or foreign firms able to pay higher salaries),
most enterprises have to Identify individuals within the enterprise, and to retrain them.
It is not easy, and need certain precautions to be successful, but it works:
the job description should be clear and precise, as well as the organisation and
responsibilities of the salesmen
the search for internal candidates should be open to any employee of the enterprise.
The chief engineer is not necessarily a good salesman, but somebody in the design
bureau, or in the administration may have some of the basic quality
the salaries and incentive schemes should be redesigned and include a significant
part of bonuses
the new salesmen should be trained. They need to acquire certain basic skills, and
this can be done either through a specific programme designed for the enterprise (a
consultant or a business school may provide it), or through the attendance to short
seminars organised by business schools for executives
it would be interesting for new sales and marketing men or women to meet some of
their colleagues in Europe to understand how they work, and how they react in a
given situation.
20
Lessons learnt
The retraining and change of attitude apply not only to sales and marketing men, but also
to all the staff. The ultimate resources of enterprises are the people, educated, trained
engineers, and workers, which will have to retool their approach to problem solving. Even
companies without financial resources can implement some restructuring actions which
will lead to an Improvement of productivity, of sales, of quality, if they retrain their staff.
Initial and significant quality improvements can be rapidly achieved by training and by
communicating with the workers.
Russia and Ukraine are part of the world economy and face competition. But they have
advantages: large markets, not yet solvent, but which should enable a number of enter
prises to have economies of scale and lower costs. Furthermore, Russian enterprises
have access to cheap and good quality raw materials (wood, energy, metals for exam
ple). Of course, these markets will also attract competitors. In some of the cases pre
sented above, the company has already found and negotiated with a partner. In the case
of textile, a joint venture is under negotiation. The rubber company had already negotiat
ed a joint venture, but was not capable to reap the fruit of the venture. Thanks to outside
assistance, they were able to Increase the European sales through this venture, and later
to secure a major financial deal (EBRD equity investment of $38 million). Some of the ear
lier restructuring cases have also ended with significant partnership negotiated with a for
eign company (Russian furniture company).
In all companies, the restructuring has been effected in the framework of a newly defined
vision of the enterprise. All the diagnosis work, and discussions with the management
team, have led to the definition of a strategy. Such clear view Is essential to prepare a
business plan, and at the end of the process, the management will be able to prepare a
sound business plan, and more important a credible one to support its negotiation to
obtain a credit or to solicit a financial investor. The company is in a position to present
Itself in a better way to a potential partner; the activity is now focused and clear for an
outsider; unrelated assets have been disposed off, the company knows its advantages,
and also its weaknesses.
While everybody recognises that the issue of social assets is critical and has to be
addressed, it is beyond the capabilities of the external assistance to help divest them.
But it can help divest some shops, for instance maintenance shops, which would be
transferred for example to the workers, and assistance would be given to design the
contract between the company and the new off-spring, and help focus the activity of the
new off-spring. The Russian or Ukrainian companies have net only to dispose of social
assets, but of assets not relevant to their core business. Most companies have already
Initiated this process, and are moving towards a leaner company.
Redundancy is another issue. In practice, it is unfortunately less Important than it
appears on the first sight. In many enterprises, workers have not been paid for some
time, or many of them are In a sort of temporary or permanent leave. The Issue there, as
Illustrated by the case of Lustk ball bearing in Ukraine, is to convince people that they
would have a better future outside the company, and as shareholders, if the company
improves, they may get benefits under the form of dividends. Of course, It is a question
Lessons learnt
21
of confidence between the management, and the workers. But important reductions of
personnel can be achieved, and should be achieved as the structure of soviet enterpris
es was not designed for a market economy.
20
Lessons learnt
The retraining and change of attitude apply not only to sales and marketing men, but also
to all the staff. The ultimate resources of enterprises are the people, educated, trained
engineers, and workers, which will have to retool their approach to problem solving. Even
companies without financial resources can implement some restructuring actions which
will lead to an Improvement of productivity, of sales, of quality, if they retrain their staff.
Initial and significant quality improvements can be rapidly achieved by training and by
communicating with the workers.
Russia and Ukraine are part of the world economy and face competition. But they have
advantages: large markets, not yet solvent, but which should enable a number of enter
prises to have economies of scale and lower costs. Furthermore, Russian enterprises
have access to cheap and good quality raw materials (wood, energy, metals for exam
ple). Of course, these markets will also attract competitors. In some of the cases pre
sented above, the company has already found and negotiated with a partner. In the case
of textile, a joint venture is under negotiation. The rubber company had already negotiat
ed a joint venture, but was not capable to reap the fruit of the venture. Thanks to outside
assistance, they were able to Increase the European sales through this venture, and later
to secure a major financial deal (EBRD equity investment of $38 million). Some of the ear
lier restructuring cases have also ended with significant partnership negotiated with a for
eign company (Russian furniture company).
In all companies, the restructuring has been effected in the framework of a newly defined
vision of the enterprise. All the diagnosis work, and discussions with the management
team, have led to the definition of a strategy. Such clear view is essential to prepare a
business plan, and at the end of the process, the management will be able to prepare a
sound business plan, and more important a credible one to support its negotiation to
obtain a credit or to solicit a financial Investor. The company is in a position to present
Itself in a better way to a potential partner; the activity is now focused and clear for an
outsider; unrelated assets have been disposed off, the company knows its advantages,
and also its weaknesses.
While everybody recognises that the issue of social assets is critical and has to be
addressed, it is beyond the capabilities of the external assistance to help divest them.
But it can help divest some shops, for instance maintenance shops, which would be
transferred for example to the workers, and assistance would be given to design the
contract between the company and the new off-spring, and help focus the activity of the
new off-spring. The Russian or Ukrainian companies have not only to dispose of social
assets, but of assets not relevant to their core business. Most companies have already
initiated this process, and are moving towards a leaner company.
Redundancy Is another issue. In practice, it is unfortunately less Important than it
appears on the first sight. In many enterprises, workers have not been paid for some
time, or many of them are in a sort of temporary or permanent leave. The issue there, as
illustrated by the case of Lustk ball bearing in Ukraine, is to convince people that they
would have a better future outside the company, and as shareholders, if the company
improves, they may get benefits under the form of dividends. Of course, it s a question
Lessons learnt
21
of confidence between the management, and the workers. But important reductions of
personnel can be achieved, and should be achieved as the structure of soviet enterpris
es was not designed for a market economy.
22
Sector
Rubber industry
Country
Russia
Activity
Assistance period
Kautschukgesellschaft
(Frankfurt)
7%
62%
Efremov's workers
2,4%
Small investors
9,6%
23
Importance in
Western
Markets
Positioning
strong
favourable
weak
Price
XXX
Quality
XXX
Reliability
XXX
Service/application
technology
XXX
Packaging
XX
Payment
+ Efremov (EZSK)
Vorenesh
Bayer
Although the quality of EZSK's polybutadiene meets western standards, and export mar
kets have been developed successfully, some issues have to be addressed, in particular
the improvement and the introduction of new grades of polybutadiene (like Cotype and
Ndtype), the renewal of the domestic sales organisation and the securing of stable and
affordable supply source for butadiene.
Finance
EZSK is geared towards its production capacity of 250 Kt per year. Under the current
market and supply conditions, if no restructuring is performed overall cash flow will
remain negative. The "related production" does not even cover its direct costs.
24
I Sales
I Contribution Margini
I Contribution Margin 2
] Operating Result
] Cash Flow 1
I Cash Flow 2
V a
V
"1
w^
The losses from social services amount to 7% of overall annual revenues and severely
hamper the cash-flow situation of EZSK.
Production
Although technology-wise EZSK is competitive on world wide markets, the production
structure of EZSK is non-integrated, non-diversified and too large for present production
levels. Focusing on core products (solid polybutadiene) should provide opportunities for
optimisation of production layout and costs.
The three main areas for improvement are the following:
present operations suffer from low capacity utilisation (50 vs. 250 Kt/y) resulting in
major inefficiencies:
- organisational (room to discontinue one major production unit)
- maintenance (generally room for improvement)
- raw material and energy (potential to improve with centralised operations).
production capacity is being maintained for very low volume products that, there
fore, cannot significantly contribute to the coverage of EZSK's fixed costs. Such activ
ities should be either developed (investment) or discontinued:
- Liquid polybutadiene (340 t/y vs. 5,000 t/y)
- Polyisobutylene (500 t/y vs. 4,400 t/y)
- Liquid Polyisobutylene (200 t/y vs. 3,000 t/y).
"non core" activities still operated: agrohoses, silica powder, PE bags should be
discontinued. They dilute management's attention, without contributing significantly to
EZSK's profitability.
25
Sales-Markets
The development of sales to defend market leadership in domestic markets and to
secure favourable market position abroad is the core of the strategy. This included the
following tasks:
- definition of a marketing/sales strategy
- improvement of marketing and sales organisation (training, set-up of the marketing
and sales departments)
- intensification of new product development activities.
Supply
As raw materials represent 75% of the cost of production of polybutadiene, competitive
and reliable supplies are key to EZSK's viability. Today's supplies come exclusively from
Tobolosk petrochemical complex. Additional Russian supplies' have to be found. EZSK
has to redesign the supply basis to ensure a constant supply of butadiene required on
competitive price base. This required the following tasks:
- definition of a multi source butadiene supply strategy
- renegotiating actual contract terms
- optimisation of logistic costs.
Finances
The main objective was to introduce monitoring and liquidity control tools to support
effective management decisions. This included the following tasks:
- introduction of a computer-aided cost controlling system
- development of liquidity management tools
- leveraging on relationships with Kautschukgesellschaft to secure export credit facili
ties.
Production
Ensuring competitiveness by improving cost efficiency, plant reliability and product quali
ty has been essential in the recovery of the company. The following actions were con
ducted:
- restructure the operations (conserve or close down production lines)
- improve the maintenance efficiency
- study the feasibility of investments in utilities (energy, water,...)
- introduce critical efficiency monitoring schemes.
M a n a g e m e n t / G e n e r a l organisation
It was necessary to adapt the organisation to "core business" needs and rethink critical
processes. The following actions were undertaken:
- agreement on a common strategic vision
- define and introduce the concept of profit and cost centres
- design the future organisation structure (introduction of new functions such as sales
representatives, financial controlling and planning)
26
27
Project references
Consultant
Supervision
28
Sector
Mechanical industry
Country
Ukraine
Activity
Assistance period
29
1992
1993
1994
1995
Consultants noticed that the factory had very little knowledge of its costs, especially in a
period when a 30% use of the production capacities resulted in a very high level of fixed
costs. These segments of the market had also varied characteristics in this respect:
in the consultants' analysis, the export sales did not allow to cover the company's
overheads in a full cost calculation. Nevertheless they were the only cash resource of
the company
the bearings were sold at higher prices on the NIS and Ukrainian markets, but on a
strict barter basis. Nevertheless the higher margins on this market convinced the con
sultants to study carefully the evolution of NIS vehicles production.
Lutsk Bearing Plant Is operating in an world market characterised by a limited number of
producers: a few world class ("quality/price") producers like SKF of Sweden, etc., and
several "low price" producers in developing countries, some of them being linked by
commercial agreements to western producers. Lutsk was unable to compete:
in terms of quality with the quality/price competitors, although its prices were 80%
lower
in terms of prices with low price competitors.
The commercial structure of the enterprise looked more like an "orders administration",
having many difficulties in taking responsibility in terms of estimates and forecasts. It was
not directed to the researching of new foreign markets, and as well unable to set-up an
efficient client-supplier relationship with the major NIS clients.
The marketing department had been just established and had no input on enterprise
commercial function at all.
Production
The production had been completed by automatic lines for forging, modern machine
tools and robots for inner and outer races, and thermal treatment equipment. 50% of the
equipment had come from Germany, the rest from Ukraine, Kazakhstan, Uzbekistan and
Russia. Depreciation rate was about 50%.
30
KEY PRODUCTION
ISSUES:
high proportion of nonflexible machinery
structure and
centralisation of energy
and process liquids
distribution which led to
increase cost
lack of the control over the
production cost
environmental pollution
and waste of energy
enormous size of the plant,
its compartmentalisation
and organisation of
production in workshops,
not on line
lack of quality control.
The factory was designed for the production of 10 million bearings but actually able to
produce 7 million, and another set of up-to-date equipment for an additional capacity of
20 million bearings was ready to be installed, when the markets would rise again.
The actual production in 1995 consisted of 2.26 million tapered roller bearings and 1.13
million needle cardan bearings represents 24% of the theoretical capacity of the plant
and 40% of the real capacity.
The production was characterised by a series of problems:
quality issue: despite some attempts at launching the ISO 9002 certification process
(but without any organisational change) and conformity with ISO 355 for the dimen
sions of the needle roller bearings and ISO 492 for the accuracy, the global quality of
the products was rather law and did not meet the export markets' requirements, out
of NIS.
range of products: whereas every major producer of bearings was offering its clients
a full range of bearings, LBP had 18 models on Its catalogue but was In fact producing
only 11 of them. This made the competitive position of Lutsk even weaker. In order to
become a major supplier of the main NIS automotive producers, the plant needed to
Increase Its offer. In order to achieve this objective, It had to be considered that about
70% of technological equipment could be characterised by a lack In flexibility. Re-pro
gramming the equipment in order to produce smaller series took up to 2 days and
caused very high losses.
production costs and price positioning: the very high proportion of Energy and
utility in the cost prices (29%) was due to the bad shape of the pipes distributing cut
ting fluids and utilities, to the leaks and the inefficient monitoring of the heat treatment
furnaces leading to a waste of gas. The quantity of defects, due to quality problems,
was higher than in western competitors factories. The experts believed that a 20%
reduction of cost prices could be obtained through investment in these areas.
Other fixed expenses, like administrative and production staff (personnel represents 17%
In the full cost structure) in the context of a low use of the capacity, burdened the costs
of Lutsk Bearing Plant.
Quality issues were also involved in the price positioning issue: the physical qualitative
aspect of the outputs remained a competitive disadvantage on the export markets and
under-pricing was the only means developed by the plant to sell its products, to com
pensate the low mage of the bearings.
Finance
Even though company had a profit of some $1,632,659 in 1995 it seemed to only
appear in accountants' documents. There was no real cash flow because 65% of sales
have been a barter-based sales. The lack of cash In the company made it difficult to pay
the salaries (up to 5 months delay) and the taxes. It was all the more difficult to launch
new productions, requiring the purchase of raw materials.
M a n a g e m e n t / General organisation
The organisation of Lutsk Bearing Plant was typical of a production-oriented company.
The newly-created commercial and marketing department was still under the control of
the powerful production director, which made it difficult to manage the production
depending on commercial Issues.
The skills of the commercial and marketing department had still to be invested:
for instance, export had always been managed by a Moscow-centralised export
organisation, and the skills for foreign trade were non-existing in Lutsk
the newly-created marketing team was too numerous and had not a clear idea of their
mission.
KEY MANAGEMENT
ISSUES:
no controlling system
traditional organisation
with main role of
production departments
over-employment if
compared with capacities
being used
rather tense social climate.
31
Quality control systems were restricted to the production sphere: there were no indica
tors, no tools for motivation for the commercial and administrative staff.
The social issue was of importance in the company. The company had understood the
necessity to decrease fixed costs, and started decreasing staff: individual companies
were created by workers leaving the company with their equipment.
In addition, the company offered a full set of auxiliary services, delivered by 300 employ
ees to the workers. They are a canteen, a recreation centre, an hospital, a greenhouse, a
farm, etc. But some social assets had already been or were going to be transferred to
external authorities (Lutsk city for instance) such as kindergarten or a hostel.
But it was clear that employment would have to be reduced further. This issue had raised
the attention of workers and of the local opinion, LBP being the main employer of the
region. Besides the traditional company trade union, Lutsk bearing Plant workers had
formed another independent Union very active to protect employment and rights.
Sales/Markets
a) Strategy
In terms of marketing strategy, Lutsk Bearing decided to:
become again a full range supplier for the main NIS clients (MAZ in Minsk, VAZ in
Nijni-Novgorod and others) and potential Ukrainian clients (Lviv buses factory, KrAZ
through its joint-venture with Iveco). For this reason LBP improves the range of prod
ucts and intensify the relationship with these clients
try taking direct contacts on export markets in order to get better margins
intensify contacts with top western supplier and be ready to make trade agree
ments with them when the company would have regained market shares.
b) Actions
Strengthening the marketing team
This department was initially heavily staffed (40), and no clear organisation to approach
markets and clients. A new commercial director was nominated and implemented an
organisation by target client groups. In a second step, the key staff of the department
received training from the consultants on the way to approach a client, manage the rela
tionship, relate to the production and finance departments. This allowed progressively
the marketing and sales aspect to become the power Centre of the company. The
department started building a comprehensive client-supplier relationship with its key
clients.
Strengthening distribution networks for the NIS
In order to achieve better sales in particular on the spare parts business, Lutsk Bearing
Plant created a network of dealers in Russia and Ukraine. These dealers were trained by
the consultants together with the company's commercial department. It was necessary
to strengthen the barter department during the transition period. This action aimed at
32
continuing barter activity and increase the share on NIS market, though improving the
quality of the barter contracts and final cash collection.
Research of direct clients
Previously, all export had been done through a Slovak company. Lutsk Bearing Plant and
this company together were able to propose a full range of production to their clients. In
order to Increase margins on export markets, the consultants advised to seek direct con
tacts with final customers, and started to take contacts together with the commercial
team. Orders for small quantities were obtained and fulfilled. In order to export directly, It
was also necessary to design a new packaging and a catalogue in several languages.
Production
a) Strategy
LBP decided to:
modify the production management rule to reduce inventories
improve quality using the equipment, purchased in 1991 in view of building additional
capacities and still in boxes, on the existing lines (this was a long decision process,
because this additional capacity appeared to many managers as a legacy which
should not be touched)
ensure a dominating position on the existing market, as It appeared that there was lit
tle hope for a recovery of the market.
b) Actions
reorganise production into three types of products according to diameters of bearings
(this would integrate tools production and maintenance)
re-engineering of workshops, with the redefinition of the role of workshop manager, to
produce the quality and the quantity necessary within a short delay
re-engineering of distribution of energy and utilities to reduce their cost
activation of the technical department to ensure the growth of the product range and
maximise the use of the available equipment
improve quality department by better integration of laboratories and auto control
strengthen the purchasing department directly linked to the top management.
33
After restructuring
Production workshop of rough shaped rollers after restructuring
Tool storage
Strainer
Calibrator
Cold stamping
machine dedicated
according to wire
diameters
LZZICZI
Spool holders
carousels
Tool storage
Strainer
Calibrator
fct\ / j j f c h /^fr\
Storage of coils
according to wire diameters
Cold stamping
machine dedicated
according to wire
diameters
cziizzi rzzi
Finance
Like in many restructuring projects, money was necessary to effectively restructure the
company. In particular, developing each model of bearings required around US$
100,000 in materials purchases. Therefore LBP had to find money inside the company:
limited staff reductions allowed to reduce fixed costs
the company sold old equipment, to Vietnam and Iran, and some of the new unused
equipment to western companies.
M a n a g e m e n t / g e n e r a l organisation
The simplification of the company structure and defeasance from auxiliary assets was
continued under recommendations of the consultants. The cooperative, which produces
the needle bearings (a totally different activity), the farms, etc. were transformed into sub
sidiaries and profit centers managed autonomously.
The social issue was treated with much care. The trade union and workers-shareholders
participated in meetings with the consultants and understood that the general strategy
aimed at developing the company and increasing production, the only policy which could
allow to contract again in the future the staff that had to be dismissed in the transition
period.
Therefore the departure of 600 to 800 non-operational staff (administrative staff, employ
ees, workers) took place in a rather good social atmosphere. Being shareholders of the
company, the workers were also informed of the discussions with foreign partners.
34
The sales in Russia have been established at a better level thanks to long-term agree
ments with Russian partners.
Beyond the increase in sales which allows to envisage a soon return to profitability, this
role as a traditional supplier of the most successful NIS producers Increases really the
value of LBP activities and the interest of potential European partners. Potential partners
will be Interested In a partnership with Lutsk Bearing Plant not so much to get lower
costs for their own markets, but to have access to other markets.
The c o m p a n y has a clear understanding of potential strategies
Lutsk Bearing Plant was initially trying to find, on the Ukrainian markets and without los
ing its independence, financial means for projects which were not attractive because
they were not based on a careful survey of the market (for instance, to finish the con
struction of a new plant). Restructuring provokes decisions which may go against tradi
tional behaviours: the new plant project was abandoned because the market would
never reach the levels expected 10 years before. The equipment which had been pur
chased was used in order to increase the efficiency and quality level of the existing lines.
Moreover, Lutsk Bearing Plant modified its strategy towards potential partners. It under
stood that the world market was under the influence of few companies, and that an
agreement with one of them would secure a presence. The company developed an
argumentation, putting forward the fact that it could help western producer to enter the
NIS market. Therefore It is today in a stronger negotiating position and can hope to
secure sufficient production level In a long-term agreement.
As a consequence of this restructuring effort, the State Property Fund decided to try and
sell the shares it owns (earlier attempts did raise little interest). Now, major western bear
ing manufacturers are fighting over these shares.
Project references
Consultant
Local consultant
35
Sector
Textile industry
Country
Russia
Activity
Assistance period
36
Rationalisation
of company
mission
\
\
/
Marketing
Engineer a
development
strategy
\
y
/
nee
Production
Organisation
37
b) Actions taken
To Implement this restructuring process, the following actions have been taken:
production, product and product development
- decreasing of waste production
- decreasing variations to obtain a more regular count
- introduction of simple quality control tools
- improvement of maintenance and maintenance planning
- development of new fabrics more appealing to consumers
marketing related issues
- introduction of basics marketing concepts in terms of price policies
- introduction of competitors analysis tools (performance evaluation, information col
lection, products evaluation, etc.)
- development of new catalogues and new sample books to send to properly defined
target customers
- development of a new more appealing packaging system
- definition and implementation of an advertising campaign
- development of exports to Increase the cash flow
administration and finance
- Introduction of international accounting standards
- introduction of a computer based managerial accounting system providing the man
agers with all the relevant information on company performance
- introduction of a new pricing system based on variable costs methodology
organisation and management
- rationalisation of the company mission and definition of a long term development
strategy to implement it
- creation of an "Executive Committee" composed of the main executives of the com
pany to support the decision process
- assistance to the general director in introducing a system clearly defining tasks and
responsibilities
- definition and introduction of the profit cost centres concept
- introduction a management by objective methodology.
38
8,000
8,825
1 Russia
+42,8%^^
S Export
7,000
^
6,000
6,179
I Total
=> 5,000
g
o
4,000
3,960
3,000
2,559
2,000
1,000
0
1?(95 (US
$)
Year
1996 (US $)
The increased export share has generated an extremely positive cash-flow to the com
pany that achieved the target to lower barter weight.
Furthermore the quality control tools and methodologies introduced have guaranteed
significant production efficiency Improvements to the company: only considering the
spinning phase, the efficiency Improvement amounts to 10%.
Development perspectives appear to be much better after the startlng-up of the restruc
turing process:
- thanks to the generated cash flow the company is investing In house-keeping to fur
ther improve the quality of the production
- the development of the Internal sales network through a cash advance payment policy
is expected to further increase company profitability and increase the competitive
positioning on Russian internal market
- an investment of approximately $5.3 million to Manufacture High Linen Count (NM 2026) to sell on the EU Market and In Russia is currently under negotiation. To guarantee
the implementation of this project, consultants assisted the company In selecting a
Russian partner with strong commercial and industrial skills and a sound access to
raw material.
- The EBRD is presently evaluating the opportunity to participate in this joint-venture
through one of the Russian Venture Fund which was offered this opportunity.
Project references
Consultant
CAST (Italy)
Supervision
General Director
Mr. Telnov
39
Sector
Processing industry
Country
Ukraine
Activity
Assistance period
40
the private enterprises held the rest (20% - 30%), with a significant domination of joint
venture companies. The weight of this sector was probably underestimated due to
non declared private construction.
Place of the company within the market
KSEP had a dominant position within Kiev market of residential construction, as the
enterprise was the main supplier of assembled and prepared plumbing, heating and ven
tilation hardware to this sector in Kiev (with a 70% market share). But no real economic,
commercial or technical barriers existed to prevent potential new competitors from enter
ing the market.
The market is oriented towards the use of new materials. The growth In demand of iso
lating and energy saving materials, related to the customers' needs for better comfort
and quality, creates new potential opportunities for business activities of KSEP.
Nearly 85% of the output Is directed to the housing construction sector in Kiev. The
importance of the public sector (KCC) remains very important for plumbing and heating
(85%) while the private demand is increasing for the other activities of KSEP (ventilation,
49% and safety doors, 40%).
Sales
In 1995, KSEP sales amounted to 50% of the level of 1992, the year when the central
planning had lost Its significance. To provide compensation for this drop in sales, the
company Introduced a new production line: safety doors. This new activity only account
ed for 4.7% of the 1995 sales. This initiative was positive but not sufficient to secure
KSEP place of the Kiev construction market.
The commercial department did not exist in 1995, and relations with customers were
handled by the production department, which had little ideas of the market's possibilities
and expectations. In addition, KSEP had to solve short term liquidity problems, due to
KCC regular delays In payments (in connection with cash shortage in the public sector)
and to inflation rate that affected the cost of supplies.
Competitors
Because of economic recession, many other companies of Kiev and Kiev region, spe
cialised in other sectors (industry, military or agriculture), started operation in the housing
construction market which was practically KSEP playground up to the recent years.
KSEP is now in competition with five other companies that supply assembled compo
nents of plumbing, heating and ventilation systems for industrial, agricultural and housing
construction. Nevertheless, except the "OZON" plant, their market penetration was very
poor, and KSEP management expected it to reduce because of these firms' financial
and operation difficulties.
Financial situation
The financial situation of the company reflected the difficulty of working with a single
client:
the level of stocks remained high and impacted on the cash management of the
enterprise. Whereas in 1994 the credit by supplier had been higher than the level of
inventories, the company was now more under pressure from its suppliers and need
ed more working capital
nevertheless the company was still profitable and viable, which is a prerequisite for
undertaking restructuring action or strategic moves in the short and medium term.
The 1995 cash flow enabled the enterprise to forecast productive self financed invest
ments.
41
Weaknesses
no distribution channels
no commercial department
high dependence from residential
building sector and a sole important
customer which is a state building
company ("Kievspetsstroi"). Its delays in
payment create shortages of working
capital for KSEP
42
Goals
Implemented actions
Management improvement
A special training programme on management techniques and pitfalls was delivered to
the top management team and study tours were organised to allow numerous contacts
with western European companies. The management information system was progres
sively set-up by the company, based on seminars organised by the consultants.
This better understanding of management techniques made the decision on a new
organisation chart more fruitful. The president of the companies started making deci
sions not on his own, but in consultation with deputy directors acquiring more responsi
bility.
In order to motivate the staff in accordance with new market needs and facilitate the
acceptance of changes, the consultants helped the company to:
assign an evaluation of each working place in the company to an external professional
firm (medium term)
determine and establish the incentive policy according to the above-mentioned evalu
ation and business objectives by areas (medium term).
Introduction into new business areas
The marketing and competition analysis showed that the company would see substitu
tion products appear and compete with traditional tubes in the near future, and therefore
had to concentrate its investment capacity on new products which would enable it to
remain a key player on the market of construction sanitary supplies.
43
S
u
>>
1 1 -
S
"3
>
^
c
->ra
>
ra
to
s.
en
> i.
"5
44
Today the company has a portfolio of more than 30 regular clients. These clients are not
merely putting orders: they have discussion with the marketing team on the needs of the
market, and KSEP is able to study in advance the development projects which will allow
it to keep a leading position.
In addition, statistics show that more than 200 different clients have been putting orders
between June 1996 and June 1997.
Nr of different
customers
Including
new customers
CO
CTI
CO
CD
"5
>
en
*-
CT)
<
o
O
CD
CD
r-
.o
(D
Li
r
en
r-
1_
"5
Q.
<
-3
en
!
<
45
Project references
Consultant
Local consultant
46
Sector
Wood industry
Country
Ukraine
Activity
Manufacturing of furniture
Assistance period
47
repair jobs, production batch marks were clearly visible on the finished product, etc. The
origin of this dismal quality was traced to various factors:
the raw material itself was of poor quality
the manufacturing process included operations done in such a way that they dam
aged the product
the procedure, when a defect was found, was to try and patch up the part so the
defect be less visible
the workers did not care about the instructions which, if properly followed, could have
led to a quality production - but also to a supplement of work
the standard against which the quality level were measured were themselves low, so
that a poor quality level by market standards were deemed acceptable by company
standards.
Sales methods
When the consultants arrived, there was absolutely no sales/marketing department, let
alone any awareness that this was a problem. There were no client records, the sales
men were given no initiative to find clients, and showed very little willingness to take any
initiative, there was no flexibility on prices, the clients were visited by different salespeople
at each visit, there was no awareness of the market situation (who are the competitors,
which is our market share?), there was no incentive for the salespeople to perform and
collect the receivable, the people at all level in the sales department had no idea of what
the client/supplier relations were in a market environment, etc. The most urgent thing
was to set up a proper marketing department, with the appropriate personal.
Design
The existing range of products could no longer be sold as:
their design rapidly became outdated, when compared to competing imported prod
ucts, mainly Polish in that market sector
they were bulky, mainly one-piece cupboards filling a whole wall in an apartment,
without the possibility to buy Individual elements, and no longer corresponded to the
buying power of the market segment they were aimed at. Smaller, cheaper and mod
ular products were needed.
Production costs
Production costs were high, which reflected of course on the possibility to sell at a com
petitive price. Among the main reasons were:
the high price and low quality of the raw material
As the company did not have the cash to buy its raw material, it had to resort to barter.
This, in turn, limited its sources of supplies to a few Ukrainian factories willing to accept
this method of payment. The result was that this raw material was markedly more expen
sive than the comparable product which could have been bought for cash, and also of a
lower quality.
energy consuming processes
This is common to all ex-Soviet factories, where the process was designed for a world
where energy was cheap but supplies of consumable or some raw materials were uncer
tain. The process may have been adapted to those conditions, but induces high costs
now that energy is expensive. For example, one machine used to bring the particle board
to the right thickness uses a heavy grinding cylinder, sturdy but heavy consumer of elec
tricity, while in today's circumstances it would be better to grind the particle board using
a light sandpaper belt, which is more expensive and has to be replaced, but which does
not require a powerful, energy gobbling, engine. The layout of the plants was also not
conducting to a proper saving in heating and ventilating.
48
49
restructuring which was essential was not undertaken. Eventually, the company could no
longer buy enough raw material to ensure a normal production, and started working part
time and sending workers on holiday without pay.
Inefficient accounting and cost accounting systems
This is a problem common to all Ukrainian companies: as the primary goal of the
accounting process is to evaluate the taxes to be paid, and as the procedures are tightly
regulated by the Ministry of Finance, irrespective of any concern about the management
of the company, the accounts end up having no actual meaning, and there is no way to
use the accounting data for management decisions.
Role of the shareholders
The situation was also complicated by the fact that the company was 100% owned by
its employees and former employees. The management was quite reluctant to propose
restructuring measures which would be most unpopular with the employees-sharehold
ers. Although the management may not have been aware of the full extent of the compa
ny's problems, it was indeed aware of the fact that strong measures had to be taken, in
particular as quality control and level of staff were concerned - and that It could not force
them upon the new employees-shareholders.
50
By the end of the project, the marketing department does exist, with a staff of some 12
people, all of them drawn from other departments of the company. The manager, a high
level technician who headed the design department, now has full responsibility for the
sales. The new marketing manager, and some of the new staff, have also been involved
In the discussions with the marketing experts of the project. This should enable them to
take into account not only the local mentality, but also the experience of the western
experts.
Introducing n e w products/designs
The consultants assisted in the process by introducing new design ideas, showing the
products of comparable western producers, studying with the design team each of exist
ing products to find how they could be improved, introducing a new logo (designed by
the design team of Carpaty).
A totally new product range has been introduced, and one of the products was awarded
a design award at the Kiev furniture exhibition. The purpose of this range is both to com
pete in design and price with foreign or local products, and to reduce production costs
through a better rationalisation of the design and the production processes. The new
products are modular, enabling the clients, who now have less buying power than
before, to buy only what they can afford. They also make use of more standardised ele
ments, thereby assisting in the cost reduction process.
Reducing the production costs
A study tour to the EU, in which the main engineers and department managers took part,
was particularly useful to start the change. It helped convince the engineers that their
equipment was not hopelessly obsolete and useless: comparable European companies
used similar, just as old, machines. They just used them in a different, more efficient way.
Translated to Carpaty's situation, it means that the investment in new machines, while
needed, is not insuperable and the company can start to improve the production
process with minor investments, changing the way its present equipment is used.
The company has since then taken extensive steps to reduce its production costs by re
deploying totally its production facilities, concentrating the machines on a more reduced
floor space, and Investing in new power and heat generating machinery more adapted to
the present energy costs and consumption volumes.
As mentioned above, the new product line also takes Into account the need to rationalise
the basic components of the whole product range. All this should result in a significant
drop in the cost of the finished products, enabling the company to be more competitive.
Diminishing the working capital
By the end of 1995, the receivable had grown unexpectedly fast, but were still within 1 -2
months of sales and remained in that range. However, most products which had been
delivered at the client's stores were not sold, and could neither be recalled (the transport
costs would have been too high), nor sold even at a high discount. Stricter credit control
methods were Introduced, a drive to recover receivable was launched, shipments in
large quantities were discontinued, which helped stabilise the situation. Attempts to
obtain immediate cash against discounts, as mentioned above, failed. On the whole, the
rise in the accounts receivable has been stopped, and they now stay at a reasonable
level.
Even more dangerous, however, was the production planning process based not on the
expected sales, but on the need to keep the workforce busy. This resulted in inflated
inventories, low sales, leading to a lack of working capital, the need to buy raw material
through barter rather than cash, thus high costs and low quality, leading to reduced
51
sales, inflated inventories, etc. While this has been pointed out to the management, it
was not stopped immediately, and during a while the management resorted to a com
promise: the production would still be kept going, whenever there was raw material avail
able, but the choice of the product would be dictated by the management. It is only
recently that the production was set closer to the sales level.
Changing the h u m a n resources procedures.
The first recommendation, valid for all departments but in particular In marketing, was to
put the right man in the right place according to a job description reflecting the current
market conditions, rather than trying to push people Into positions they would not be
able to fill successfully.
A greater flexibility has been established. This is being translated In the organisational
structure of the company, with branch directors taking full responsibility for their sector.
This should normally result in a transformation of those production department into sub
sidiaries, reinforcing the independence of their managers. Still, as the company cannot
propose decent salaries and career opportunities, outside recruitment is not possible
even when the necessary skills are not sufficient within the company. This is one of the
main present problems, as some departments (marketing In particular, which is vital for
the survival of the company) are unlikely to be staffed by internal recruitment only.
Changing the accounting procedures
The cost accounting system was totally irrelevant for managing the company. This was
done in particular by literally dissecting the accounting and the cost accounting systems
to show their flaws. A change in the accounting and reporting system has been promot
ed, while being aware that this would actually translate into a double set of accounts,
one according to the tax procedures, the other according to more decision-oriented
accounting systems. The management is now perfectly aware both of the needs and of
the ways to implement a more decision-oriented information system. In particular, the
cost accounting system has to be totally redesigned. There is no way to assess, today,
the actual profitability of a product line or of a marginal production. A computer is being
implemented to assist in the related number-crunching. However, no real change, short
of a costly double set of accounts, can be taken while there is no real accounting reform
in Ukraine.
52
a new information system is being implemented, with a financial staff fully aware of the
new needs and methods
the production costs have decreased by 20 to 50% depending on the shop and the
machine.
More generally, the company is now recovering, after some deep changes, albeit at a
reduced capacity, while most of the competing firms which do not have a foreign partner
are now idle. First of all, the vicious circle which existed at the beginning of the project bad quality, low sales, low salesmanship, high inventories and high receivable, leading to
barter, blocked accounts, low quality of raw material and production, low sales - has
been frozen. Frozen but not definitely broken yet, as some of the main components
which will enable this reversal are only now beginning to be put in place: the new market
ing department has just been set up, the lay out of the factory and the production
process have been only recently modified, the production planning process Is being
reviewed, the management information system is still to be put in place, and more Inde
pendence Is being now given to the managers. Taking into account the depth of the
changes this represents, the implementation of all those changes Is slower than it would
be the case in a similar western European enterprise.
The structures are now in place to foster the recovery. This recovery is assisted by a
quasi moratorium on debts to the tax authorities, but will require more training of the
sales personnel, a continuation of the restructuring which already took place, and proba
bly financial inputs. The critical point will be the financing, as the past losses have left the
company with a disastrous balance sheet (taking into account inventories which will
never be sold) and insufficient funds to finance its recovery. Outside financial assistance
will be necessary.
However, the company now has all the weapons that may be necessary to look for a
partnership, industrial or financial.
Project references
Consultant
Local consultant
53
Sector
Pharmaceutical industry
Country
Russia
Activity
Generic drugs
Assistance period
54
Russia
Eastern Europe/
India/Turkey
Cumulative average
growth rate:
Market: 30%
Western drugs: 70%
Eastern Europe/India/Turkey: 37%
Russia: 10%
1993
Western drugs
1996
55
56
selecting cost efficient national distributors with strong regional coverage and by actively
managing distributor relationships both at the national and regional levels.
Akrikhin must review product profitability based on more advanced manageri
al accounting techniques
The traditional method of overhead allocation based on proportion of salaries skews
profitability measurement. Adoption of an alternative product cost accounting approach
with more direct overhead cost drivers revealed that many low-price Akrikhin products
are either loss-making or marginally profitable, and should be considered for possible
discontinuation.
The company must expand in-house product development capabilities
New product introduction has to be the key driver in Akrikhin sales gains. The company
spends significantly less on R & D (as a percent of sales) than analogous generic compa
nies. Alliance with foreign companies in joint production of new products is likely to be a
key to growth in the short and medium term.
Significant cost-cutting opportunities have to be identified
Inflated manpower and Inefficient labour productivity especially In indirect areas inherited
from the company's past as a producer of chemical substances may be significant costcutting opportunities. The company needs to identify areas for restructuring, and to cut
staffing of overhead departments.
Actions taken
a) Establishment of a field sales force
The Sales Division was created at the company based on the consultants' recommenda
tions, with the new sales function and the order taking/logistics function organised as
two separate units.
In 1997, Akrikhin prioritised the recruitment of 15 field sales representatives to work in
regions identified as strategically attractive, where the company's distributors were not
present. By midyear, the company had 10 regional sales representatives located In St.
Petersburg, Oriol, Novgorod, Tyumen, Irkutsk, Ekaterinburg, Rostov-on-Don,
Krasnoyarsk, Saratov and Cheliabinsk. In September, Akrikhin anticipated hiring an addi
tional 5 sales representatives to cover the Ufa, Novokuznetsk, Perm, Khabarovsk and
other regions. The new sales representatives were allocated to macro-regional centres,
from where they co-ordinate company sales activities In surrounding Oblasts. This
makes Akrikhin one of the most advanced Russian pharmaceuticals companies in terms
of sales organisation and puts the company in an advantageous position to realise the
ambitious growth targets set by management.
This sales force is necessary to match the set-up of competing Eastern European pro
ducers such as Gedeon Richter, the Hungarian company with a leading position in the
Russian market which have around 50 sales reps across the Russian Federation.
Akrikhin's sales representatives have been engaged In maintaining wholesaler relation
ships and developing new wholesaler contacts and are commencing sales activities tar
geted on pharmacies. Akrikhin is currently developing advertising materials for both
doctors and point-of-sale at local pharmacies. Eventually, the company plans to split
sales force efforts equally between wholesalers vs. doctors and pharmacies.
Akrikhin designed a standard contract for field sales representatives, with compensation
consisting of a base salary and variable commission. The commission portion directly
relates to company sales levels in the relevant region.
57
# to be visited
by salesforce
Average number
per oblast
Coverage
% in oblast
Distributors
15
(3 per oblast)
many
but 15 are attractive
100% of attractive
wholesalers
Pharmacies
120
200
60%
16 growing to 32
250
12%
60 growing to 120
7,000
2%
Polyclinics
Doctors
58
59
And finally, the project led to tangible results: in the first months of 1997, Akrikhin's
monthly sales revenues increased to 25 billion roubles ($4.5 million), the company's high
est sales ever realised (compared to 20 billion at the end of 1996). In September, man
agement was targeting annual sales revenues for 1997 of 350 billion roubles ($60
million). Recent product introductions, Aciclovlr-Akri (Zovirax generic equivalent) and
Biseptol, contributed to the company's high performance.
Project references
Consultant
Supervision
60
Tel. 52 88 03
Azerbaijan
Tel. 93 60 18
Belarus
Tel. 27 32 39
Georgia
Tel. 99 96 02
Kazakhstan
Tel. 63 99 39
Kyrgysstan
Tel. 22 57 89
Moldova
Tel. 23 30 37
Mongolia
Tel. 3110 13
Russian Federation
Tel. 956 36 00
Tajikistan
Tel. 21 26 09
Turkmenistan
Tel. 512117
Ukraine
Uzbekistan
Tel. 293 14 83
Tel. 39 40 18
61
Questionnaire
LJ
enough
too li ttle
J
J
J
J
J
J
J
J
J
J
J
J
J
acceptable
difficult to
understand
_l
LJ
LJ
LJ
_l
I
LJ
For each of the sections below, rate the benefi t you could
draw from the i nformati on gi ven in the document
useful
not particularly
useful
useless
LJ
_l
LJ
LJ
LJ
LJ
_l
J
J
J
LJ
62
Questionnaire
For the whole document, rate the relevance of the i nformati on,
given the speci fi c envi ronment you work i n
LJ relevant
D acceptable
good
D poor
LJ in the administration
LJ in a training Institute
Q in a consulting firm
LJ other (precise)
other (precise)
In w h a t regi on?
Tacis
Other comments:
The Tacis technical
dissemination project
Some examples of
successful
restructuring
experiences
European Commission
S o m e examples of successful restructuring experiences
Luxembourg: Office for Official Publications of the European Communities
1997 64p. 21,0 29,7 cm
ISBN 92-828-2219-2
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