Category Archives: Supply Chain

How Do You Identify Tomorrow’s Supply Chain Paupers?

They still use paper today.

Although I don’t understand how any supply chain focussed business, and a logistics carrier in particular, could still be paper-based. It blows my mind that the WT 100, in their recent article on “Rounding the Optimization Curve”, reports that there are still a significant number of carriers that keep their records on paper. How can you survive in today’s cost-competitive, just-in-time, value-conscious supply management landscape and work on paper?

And while we’re at it, let’s talk about how you can identify the dead men walking of the day after. They use Excel. We’ve known for years that errors in spreadsheets are pandemic. Needless to say that it boggles my mind that Microsoft Excel continues to be the application of choice for supply chain and logistics management around the world. Fidelity lost 2.6 Billion as a result of a spreadsheet error, Fannie Mae made a 1.13 Billion honest mistake, and RedEnvelope lost more than a quarter of their value in a single day after they warned of a fourth-quarter loss due to a budgeting error that resulted in an overestimate of gross margins. How long is it going to be before someone accidentally uses a plus sign instead of a minus sign in a profit formula and forgets to uncap an inventory calculation and instead of ordering 100,000 units of a profitable product, instead orders 1,000,000 units of a product that actually results in significant losses at the target sale price, for which the market demand is weak, ties up all of the organization’s working capital, and essentially bankrupts the company? My guess, with the steadily increasing complexity of S&OP, JIT inventory management models, and supply chains, not much longer. But, maybe after a few companies are brought to their knees from spreadsheet errors, we’ll see the day when Excel is sh!tcanned along with the dinosaurs who still think it has any more use than a HP or TI calculator.

It’s time for anyone still on paper or Excel to wake up and realize we don’t live in Walt Disneyland and that the story of the prince and the pauper is a fairytale. A pauper is not going to become the benefactor of princely riches just by looking like a bigger, richer, company. In today’s uber-connected world, appearances don’t account for much. It’s not long before someone digs deep and uncovers the truth.

There’s a reason why customers are demanding end-to-end visibility of their supply chains, including those of their supply chains logistics’ partners. And a reason customers ow expect all of their suppliers and business partners on the supply chain (including logistics providers) to participate in a supply chain social network. It’s because they know that the only way they can accurately manage their supply chain is to keep on top of it, that the only way they can build accurate models is with accurate data gathered from partners, and that the best reports they are going to get are going to come from supply chain visibility and planning software plugged into these “social networks” (where, in reality, these are “enterprise communities” that allow the necessary collaboration, not “consumer networks” where you can poke, prod, and shake your buddy for no apparent reason).

In other words, paper is dead, and Excel will be the new paper, and then, someday, it too will be dead. So if you don’t want to be the pauper, move off of these technologies and onto solutions designed for your supply management needs. With a plethora of Best-of-Breed solutions on the market, designed for large and small providers, it’s extremely likely that there’s at least one solution that meets your needs almost exactly with minimal tweaking. If you look hard enough, the doctor would bet that there’s at least three, or will be before you can look twice.

Will Factories in a Box Revolutionize Sustainability Initiatives?

Gizmodo just ran a very interesting, and vey insightful article on how “The Next Industrial Revolution Starts in this 20-foot Shipping Container” about Re-Char and their “Shop-in-a-Box” that can perform rapid fabrication of steel parts by way of software and a CNC plasma torch. With the Shop-in-a-Box described in the article, Re-Char can produce 600 lids for Climate Kilns. This is a specialized lid-and-chimney integration that adapts a 55-gallon drum to produce the soil amendment biochar. (In Kenya, farmers burn sugarcane debris in an open field and release tons of carbon. A Climate Kiln controls the burn to produce the carbon-rich charcoal biochar that, mixed into soil, reduces the fertilizer requirements for crops by half.) This required the precision cutting of 18-gauge metal, which, in East Africa, leaves you the option of using a guy with an oxy-acetylene torch on the side of the highway or importing a full production run out of China, one full shipping container at a time. But for 30,000, Re-Char was able to produce a Shop-in-a-Box metal cutting and joining setup that could be run by two two people and produce 600 lids as a time, when needed, where needed (as the shop in a box can be moved to a new community when the needs of the current community have been fulfilled).

From a sustainability perspective, this is incredible. It’s lean, green, and completely against the routine. Actually, lean is an understatement. The power requirements are limited to what is needed to produce the lids. The energy required just to light, cool, etc. an average factory typically takes a 600 V feed … or two … or three. It’s green in that it can be powered by sustainable energy, including wind power, water power, or solar power – whatever is available. (Transformers come with the standard kit, along with generators for [natural] gas power for stability. Just add batteries and a UPS and it’s 100% green power most of the time.) And it’s completely against the routine. When the industrial revolution started, you can be that the robber barrons never predicted a moveable factory.

To date, the most (wide-spread) innovative use of containers has been data center modules, with Google a leader in this technology. (But this has been taken to the next level. For example, Green Data Center has designs for completely self-contained data center modules that you can drop anywhere. Just hook-up a power feed and an internet feed, and you’re literally good to go. (And since you can easily put a generator, or two, in a second container, you don’t even need a power feed. Just a natural gas feed, split between a couple of generators if you don’t have a sustainable power feed, for a primary feed.)

But we don’t have to stop at data centers and steel-part fabrication shops. Especially when we are talking about the developing world (which still includes much of Africa, South America, and parts of Asia). Do we really need to refine cane sugar 2,200 kgs at a time, for example? Or how about water purification? If we’re talking about a small community of a couple of hundred people, and the primary focus is clean drinking water, we don’t need to purify 100,000 liters a day! Purifying 1,000 liters would do nicely! Both processes would fit nicely in a container system. (After all, the sugar refinement process is not radically different from micro-brewing in terms of what is needed, and you could fit that nicely in a container too — although we can’t necessarily bring the same humanitarian arguments if we did.)

And when we’ve insured that everyone has the absolute necessities of clean air, clean water, and healthy food — we could ship them clothing factories in a box. It doesn’t make sense to sew shirts in sweat-shops on another continent just to ship them to small communities in Africa, or South America, or Asia, where the living wage is $2 a day or less. Considering the shipping costs alone, you couldn’t set the price at a point where you’d make many sales. Just ship a container to the town, train a few locals on the cloth-cutting production lines and find a few budding seamstresses to do the stiching, and produce the clothing where it will be sold. A zero-mile supply chain that emits zero-carbon and has zero shipping costs. And since you don’t have time-sensitive fashion industries in developing economies, you could even rotate it between a few small communities in the beginning while the consumer base and local economy built up. (Hopefully you’d also move the employees too if they were willing, as you could outfit another container as temporary living quarters without much cost or effort.)

I think the physical manifestation of the Solution-in-a-Box approach has the potential to revolutionize manufacturing, distribution, and sustainability. And it’s not like we have a shortage of containers thanks to the outsourcing craze of the last fifteen years. They’re just sitting there waiting for a good use. And with all the super-panamax ships, and super-panamax capable ports, that we have at our disposal, we can get them from any continent to any other continent with ease, in bulk, and pretty close to where we want them. And then we just need a freightliner to haul them, and there’s no shortage of those.

Do You Know What’s At Risk? Resilinc Does!

Resilinc, a new player in Supply Management, has a unique approach to identifying and evaluating risk in your supply chain. Eschewing the transaction-and-finance focussed approach of other players in the risk management space, and building on the lessons learned from SIM (Supplier Information Management) vendors, Resilinc has built a unique approach to identifying and quantifying the relative risks in your supply chain.

Started by a Risk Management practitioner in the high-tech and electronics supply chain, who has a Masters in Engineering in Logistics (from the Massachusetts Institute of Technology), Resilinc not only builds on the lessons learned from SIM, but on the lessons learned from real risk management practitioners and specifically focusses on the electronics and high-tech, medical device, and automotive supply chain – realizing that, when it comes to risk, not all supply chains are created equal.

So what is Resilinc? It’s an affordable DSS (Decision Support System) for larger mid-size and large multi-nationals that need to

  1. identify the most significant risks in their supply chain,
  2. keep tabs on what facilities may be impacted by a significant external event, and
  3. be immediately informed when an event could cause a disruption that requires immediate action.

The solution, delivered using the SaaS (Software-as-a-Service) model, does this by tracking all of the relevant information on each supplier and facility in your organization’s multi-tier supply chain. Whereas a typical SIM solution (that powers a typical financial risk analysis product) will track each supplier, their official information, their insurance certifications, their corporate addresses, etc., Resilinc’s solution tracks each individual manufacturing facility, the products produced at those facilities, the inputs required, the lead times required, and the time taken to get the plant up and running again as a result of a serious disruption (such as a natural disaster, border blockade, strike, etc.). Based on this information, integrated financial and location risk metrics imported from other systems (for which you have a license for), and the relative revenue impact of each product on your total organization revenue, Resilinc is then able to

  1. provide an overall risk score, delivered in terms of the revenue impact of a disruption, for each location and product,
  2. give you the ability to determine the impact of an external event in a given location with respect to supplier locations and sourced products, and
  3. determine which locations and products are likely to be impacted by a significant event anywhere in the world, as soon as it happens (and e-mail you a notice that the event — which may be an earthquake, war, or labour strike — is potentially impacting one or more locations in your supply chain).

Risk Managers can use this to determine which locations and products have the biggest risks, which facilities will be impacted the most as a result of a supply disruption in an area, and which product (line)s are at risk as the result of an event that just happened. And then they can take action.

Resilinc is a powerful tool for the high-tech, medical device, and automotive supply chain, which, until now, were probably too reliant on financial metrics, which are not the only risks one needs to be concerned about in a multi-tier supply chain.

The Looming Strike Might Cost Billions – But You Don’t Have To Lose a Dime!

A recent article over on Fox Business on how the “looming strike could cost billions” if all of the east-coast US ports are shut down on Oct. 1 (because of a strike) is scary, unless you are a multi-national who has the option to simply shift your freight North or South. While such a shift might not be optimal for you, as it will require you to build new supply lines, secure new cross-docking and storage facilities, and, hopefully, use new free-trade zones (and become familiar with the optimal utilization of such if you aren’t already using them) at a time when you are ramping up for the holiday season, not only might such a move prevent you from experiencing losses (that could lead to ruin if the strike was a long one), but it might even save you money in the long run!

While often overshadowed by their southern and northern neighbours, Canada’s ports and Mexico’s ports are open for business, and some have been expanding their capacity significantly in recent times. For example, as recently pointed out in Halifax Gets It There dot com and summarized succinctly on the Port of Halifax site, the Port of Halifax has an ample supply of empty containers, no congestion, and capacity to space at its terminals and on rails. Plus, it already has 11 of the world’s top 15 global shipping lines and the capacity to handle up to 2.5 M TEUS. This is almost the TEU volume of The Port of New York and New Jersey. Plus, the Port of Montreal can handle 1.6 M TEUS! Now, it’s true that Montreal is currently at 80% of capacity while Halifax is barely at 30% of (projected) maximum capacity (remembering that Halifax is situated on the second largest natural harbour on the planet), but the Port of Montreal is also in the midst of the first phase of a major expansion project that will increase capacity by 15% in less than two years. And in New Brunswick, for those looking for a smaller port with less competition, there is the Port of Saint John which can handle 150,000 TEUs.

In Mexico, you also have a number of ports to choose from, including the port at Altamira, the port at Tuxpan, and the port at Progreso. As far as I can tell, Altamira can handle at least 50,000 TEUs, Tuxpan is building a facility to handle at least 90,000 TEUs, and Progreso can handle a whopping 300,000 TEUs per year. Not the volume of the big East Coast Canada ports, but nothing to sneeze at either — and Mexico has five more ports on the Gulf.

So redesign (at least some of) your supply chain now to use Canadian and Mexican ports, and you won’t have to worry about losing a dime if the East Coast US Ports go on strike.

BizSlate, an ERP for the Small to Mid-Size Distributor

If you’re a small to mid-size distributor, with revenues under 100 M who is still running on QuickBooks (or even Microsoft dynamics), BizSlate is an ERP solution that you should be looking at — right now! BizSlate is doing for small-and-midsize distributors what Compiere and Made2Manage, are doing for small-and-midsize manufacturers — bringing usable, affordable ERP with exceptional supply chain support to the masses. And even though the official release of V1 doesn’t come out until Q4, BizSlate is already approaching two dozen distributors who are already using the solution, almost a dozen of which pre-paid for it over a year ago to be part of the usability design team.

With the sheer amount of data an organization needs to keep track of these days from an e-procurement, e-sourcing, spend analysis, risk management, and compliance perspective, it’s almost impossible for an organization with more than 10 Million in revenue to do without an ERP, but given that the annual total cost of the big ERPs still end up being in the seven figure range once implementation, training, maintenance, and infrastructure are factored in, these solutions are not affordable for the average small or mid-sized business. And while there are a number of SaaS best-of-breed solutions in each of the aforementioned supply management areas (like Coupa, iValua, Iasta, BravoSolution, BIQ, SupplierSoft, Vendormate, Lavante, etc.) that will allow an organization to collect and retain all relevant data, this data still needs to get into a centralized data store for inventory, warehouse, and logistics management; accounting; and spend analysis — a central data store that should probably take the form of an ERP solution. (And we recently pointed out how best of breed on an ERP backbone provides the best of both worlds.)

But not any ERP will do if you’re a small to mid-sized distributor. It has to be lightweight (as small to mid-size organizations don’t have the needs of large multi-nationals), SaaS (as they don’t have the IT departments either), low-cost (as they also don’t have large software budgets), and come in default configurations appropriate for distributors in different verticals (apparel, food & beverage, pre-manufactured components, etc.). And while Compiere and Made2Manage do well in the manufacturing world, and for the distributors who handle manufactured components and electronics, it can require some consulting and effort to customize them for apparel and food and beverage distributors, especially for certain organizations with certain processes.

Enter BizSlate. Before they spun it off from Ezcom software, the founders of BizSlate — who were focussed on low-cost EDI solutions for retailers — noticed the lack of appropriate ERP support for the small and mid-sized retail and distribution space, and decided to do something about it. Over the past year, they have designed a new SaaS-based ERP from the ground-up that addresses the everyday accounting, inventory, catalog management, and order management / e-procurement requirements of small and mid-sized distributors through a simple web-interface that is as easy to use as most of the new SaaS enterprise e-Procurement systems on the market. And they did it with the unique needs of the retail distribution space in mind.

The importance of their focus on the retail space, and the apparel space in particular, cannot be overlooked. In this space (as in food and beverage, but to a much greater extreme), it is generally the case that each distinct instance of a product (which is often a combination of colour, size, and style) needs to be its own line item and have its own SKU. As a result, setting up a clothing line in a traditional ERP system can often require days of manual entry as a user often has to create up to 100 products just to handle one shirt (10 sizes * 5 colours * 2 styles). If an average clothing line contains six shirts, two sweaters, four pants, three jackets, etc., and four new clothing lines are being carried, it is easy to see how thousands of new product records might need to be created in a traditional ERP, making the data entry so egregious that the ERP is almost unusable. In BizSlate, an administrator can batch-create new products simply by entering all the base product information and then defining the characteristics that define different instances and the set of values for each characteristic. A user can create hundreds of combinations in a matter of minutes.

In addition, they also looked at how orders were created and came up with bulk order template functionality that allows a user to quickly generate an order form for a product group, with a line for each instance of each product in the group, and a default order quantity for each group, or product. As a result, a user can generate an initial start-of-season order in a matter of minutes as all the user will have to do is change a few order quantities.

And this focus on process support is not limited to product and order creation. They also looked at the inventory management and accounting processes and made each step as easy as they could for the average user, focussing on collecting only the information that is required and only when it is required. The entire goal of the design is to keep the user out of the system as much as possible as success in this space depends on selling and generating orders, and then optimizing the inventory levels and logistics, not on mucking around with an ERP or trying to optimize pennies when the volume doesn’t exist to achieve FTL discounts from a big carrier.

As they are only in the process of releasing V1, there are still a few week areas, such as reporting which is limited to canned reports and accounting which only supports GL integration with QuickBooks, but even the functionality in these areas supports 80% to 90% of the needs of a typical distributor in retail or a related channel. V2, slated for Q2 next year, will have a fully integrated report writer, a (punch-out enabled) shopping cart, and support for carrier integration. But from an efficiency perspective, which was their goal, they’ve hit the nail on the head. The manpower savings alone will more than pay for the solution, and the value that a company will be able to generate through even the most basic spend analysis effort after deploying the solution for a year will be substantial.

In summary, if you are a small to mid-sized distributor, with revenues under 100M, in a retail vertical, and you don’t have an ERP, BizSlate is one company that you have to check out. They’re on the right track, and once you have your data in a centralized data store, bolting on a best-of-breed e-Sourcing or Spend Analysis engine will be a breeze, and your savings will multiply. (And yes, the doctor hasn’t been this impressed with an ERP effort since the early days of Compiere.)