Monthly Archives: June 2009

The Lean Guru

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According to a recent article in Industry Week, the basic principles of lean — waste reduction, customer centricity and flow optimization — are fairly simple in theory but when it comes to putting lean principles into practice, even the most well-intentioned manufacturers can run up against some roadblocks. That’s why many manufacturing firms begin their lean journey by seeking the counsel of a consultant … a lean guru.

The article makes a great point. A consultant brings more to the table than simply helping organizations conduct kaizen events or create value-stream maps. Hiring a consultant is an excellent way for management and leadership to signal a change within the company and to use the consulting event to define and formulate a revised purpose or a reason for being. This helps you get lean on the fast track, and considering that lean is a great fix for a down economy that can help you sense demand, source successfully, streamline services, and reduce inventory, which reduces waste and lowers cost, how can you go wrong? Especially when Consultants are Cheap.

Are We Moving Away From China?

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Editor’s Note: This is Dick Locke‘s third post as a regular contributor on Sourcing Innovation. (His previous guest posts are still archived.) Dick, who has delivered seminars to over 100 companies across the globe, is a seasoned expert on International Sourcing and Procurement who wrote the book.

I just read through AMR Research’s “Supply Chain Risk, 2008-2009: As Bad as It Gets“. It rightly points out that it’s been a scary year. It does do a very thorough job of criticizing China. I know that AMR is just reporting what their clients report to them so I can’t fault AMR for what they say.

Among the things they say

     China is the world capital of supply chain risk.

And, because of such concerns,

      The move away from China sourcing starts with higher value-added work, boding ill for the Dragon’s ambitions to outdo Japan’s ascent from a cheap labor to high-tech economy.

If such a move has taken place, it’s not apparent yet in the computer industry.

Here are statistics from the US International Trade Commission: HTS 8471 is computers and peripherals. Data is January through April.

Country   2008 YTD 2009 YTD Percent Change
Thousands of dollars YTD2008 – YTD2009
China   $9,101,153 $8,407,280 -7.60%
Mexico   $1,734,089 $1,863,850 7.50%
Malaysia   $3,166,961 $1,150,911 -63.70%
Thailand   $1,138,875 $818,513 -28.10%
Singapore   $953,493 $543,373 -43.00%
Japan   $537,601 $383,673 -28.60%
Canada   $280,130 $232,428 -17.00%
Taiwan   $276,369 $207,521 -24.90%
Ireland   $221,564 $171,436 -22.60%
Hungary   $244,124 $147,130 -39.70%
Philippines   $234,714 $130,273 -44.50%
Germany   $125,194 $104,954 -16.20%
United Kingdom   $103,245 $94,534 -8.40%
Korea   $152,459 $88,018 -42.30%
Israel   $47,296 $52,556 11.10%
 
Subtotal:   $18,317,267 $14,396,450 -21.40%
All Other:   $290,471 $211,065 -27.30%
Total:   $18,607,738 $14,607,515 -21.50%

Sources: Data on this site have been compiled from tariff and trade data from the U.S. Department of Commerce and the U.S. International Trade Commission.

Comparing the first four months of 2009 to the same four months of 2008, computer imports into the United States dropped 21.5% in value. Imports from China only dropped 7.6%. China is increasing its share of imports.

I don’t think this is a sign that computer manufacturing is returning to the U.S. However, one sign that nearshoring may be taking hold is that Mexico is one of only two countries whose absolute value of imports increased. It jumped from number three country to number two.

These USITC reports are especially useful when sourcing. Look for both high value countries and rapidly growing countries. Your best sources will probably be in those countries.

Dick Locke, Global Procurement Group.

Social Networks ARE a Disruptive Scourge

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… and despite what Phil Fersht says, we should not embrace them. I could write a five page essay on why we should outlaw them, but since they’ve given all of you ADD (Attention Deficit Disorder, if you’ve gotten this far), I’ll get to the point.

If you and your employees are checking your tweets every five minutes, how much work are you getting done? The answer: very little … at a time when your smart competitors who have banned MySpace, FaceBook, and, most especially, Twitter, from the workplace are running circles around you. There’s a place and a time for Web 2.0, and where most of today’s instantiations are concerned, the office is not one of them. It’s one thing to incorporate the useful components of the technology to allow your global workforce to come together, collaborate, and share ideas like RollStream did (which I do recommend) … but it’s another to allow your employees to follow sockington the cat on Twitter on work time. Think about it.

The Troubled Triangle — How an Economic Recession Can Increase Fraud

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Editor’s Note: This post is from regular contributor Norman Katz, Sourcing Innovation’s resident expert on supply chain fraud and supply chain risk. Catch up on his new column in the archive.

In the 1950’s, Donald Cressey, a sociologist and criminologist, created the theory of the Fraud Triangle. In brief, Cressey stated that there are three components that must all come together for the commission of a fraud to occur. (This is akin to a “three-legged stool” theory.)

First, there must be pressure. A person can feel pressure from a variety of internal and external sources, such as a desire to excel, jealousy, family needs, drug or gambling addictions, etc.

Second, there must be opportunity. If a person senses that he/she can get away with something, or is otherwise enabled to do something, opportunity is present.

Third, there must be rationalization. A person will think through why an act of fraud should or should not be performed and “talk themselves into” the belief that the fraud should be perpetrated, often using skewed logic which seems justifiable to the person.

Now, let’s relate Cressey’s Fraud Triangle to the troubled economic times we are in. Organizations are slashing payrolls and laying off personnel by the hundreds and thousands. While this may satisfy financial analysts and Wall Street, are these moves being thought out strategically in terms of security and good governance integrity? Let’s explore this.

For the remaining employees, I’d imagine that these folks are under a lot of pressure, having to pick up extra work loads that their now laid-off compatriots once did. With work loads increased, bonuses cut, existing payrolls held or reduced, and the worry of whether they will be in the next round of cuts should their organization survive at all, there’s a lot of pressure on the shoulders of these individuals. Combine this with outside-the-job pressures such as family needs, an unemployed spouse, kids in college, medical care, etc. and you’ve got quite the boiling tea kettle ready to blow.

With their job responsibilities increased to cover for dismissed colleagues, an employee will likely need more business software application rights and roles to accomplish the new expanded set of tasks. By increasing application rights and roles, a single employee could in fact be given enough authority to perpetrate fraud. (Remember our friend the accounting clerk who I mentioned in a previous post?) Job cuts often result in decreased monitoring and controls, overall leaving an employee with ample opportunity to commit fraud.

Now, with pressure building and opportunity soaring, what’s left to reign in the otherwise honest employee from perpetrating fraud? It is our morals, ethics, values, and principles. And when these fail – when the forces of pressure and opportunity become so great that they eclipse this final protective barrier, there is a good likelihood that fraud will be perpetrated.

For public companies that must comply with Sarbanes-Oxley laws and ensure good governance to protect their financial statements from materially significant impacts, are the corporate cuts leaving them exposed to even more risk from fraud than before? (Private companies and government agencies face the same risk exposure too.)

Have you had to cover for colleagues that were let go? Are there more gaps and less controls now than before? Are you one of the many who was made redundant and know that your absence has created or widened a gap where fraud can now foster and grow? Let’s hear from you.

Norman Katz, Katzscan

Does Scenario Planning Trump Location in Supply Chain Friendly Network Formation

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A recent Industry Week article on how to develop a supply chain-friendly network stated that scenario planning considerations can be just as important as location. The rationale is that, in response to the 2008 fuel spikes and recession, many companies are repositioning their logistics locations closer to end users and increasing inventory levels to insure full truckload shipments in a knee-jerk reaction. As a result, inventory overhead costs are climbing to unacceptable levels and product obsolescence is becoming an even greater risk than before. And the article makes a valid point.

But is real estate scenario planning, that addresses the likely results of adding to or changing your network sites, the answer, or is it full fledged network optimization backed by decision optimization technologies? While, as the article suggests, you need to look at and collect labor availability and rate, government incentive, required inventory level, transportation mode and rate, and warehouse operating cost data for each location under consideration, the only way you’re going to truly be able to understand the total cost of each potential decision and select the best, lowest-cost, network design that meets your service level requirements is with a network optimization tool as there’s just no way your spreadsheet calculations are going to capture all the costs, constraints, and business rules you’re going to identify in your scenario analysis. So while scenario planning is important, ultimately, the answer is selecting the best locations, and I would submit that can only be done with the aid of good network optimization tools.