Products & Sales Analysis Raw Material Analysis Combined Analysis of Raw Material Product & Material Management Dashboard RUNNER Repeater Stranger I - 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000 12,000,000 30 90 120 156 A RM Stock A/RRS/LT Classification A - 2,000,000 4,000,000 6,000,000 8,000,000 10,000,000 12,000,000 14,000,000 30 90 120 156 X RM Stock A/X/LT Classification Demand Behavior Runner Repeater Stranger Cost of Goods Sold 50% 15% 35% Volume 60% 20% 15% Avg. Order Size High Medium Low Number of SKU's Narrow Mid Wide Customer Order Size Large, Constant Midsize, Constant Small Frequency of Change Over Low Medium High Order Winning Criteria Price, Delivery Price, Delivery Mfg. Capability 0% 20% 40% 60% 80% 100% 120% 140% Jan Feb Mar Apr May Jun Jul Aug Sep Oct Nov Dec Series1 91% 99% 125% 88% 102% 116% 119% 113% 91% 77% 87% 92% 125% 119% Average Monthly Sales = 15,855 Units CV= 0.150497 < 0.75 - 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 Jan-05 Mar-05 May-05 Jul-05 Sep-05 Nov-05 Jan-06 Mar-06 May-06 Jul-06 Sep-06 Nov-06 Jan-07 Mar-07 May-07 Jul-07 Sep-07 Nov-07 Jan-08 Mar-08 May-08 Jul-08 Sep-08 Nov-08 Jan-09 Mar-09 May-09 Jul-09 Quantity Sold 12 Month Moving Average of Runner Products Quality Lead Time Service Level Cost Quality Lead Time Cost Order Winer Design Capability Service Level Cost Service Level MRP KANBAN Order Winer Quality Cost Design Lead Time Cost Quality Lead Time Quality Lead Time Service Level MTO MRP Satge of PLC Introduction Growth Maturity Saturain Decline Damand Chain Strategy DTO KANBAN Product Life Cycle and Corresponding Supply Chain Demand Chain Strategy Order Qualifier Stage of PLC Sustain 0 10 20 30 40 50 60 70 80 Suppliers Inventory In Transit to Factory Raw Material Inventory WIP Work In Process Finished Product Inventory In Transit to Distributors Distributors Inventory Retailers Inventory Mapping the Total Supply Chain Inventory 19.0% 10.6% 0.0% 96% 100% 100% 0.0% 10.0% 20.0% 30.0% 40.0% 50.0% 60.0% 70.0% 80.0% 90.0% 100.0% X1 X2 X3 X4 X5 X6 X7 RRS Sales Calssification % % Cumulative Runners Repeater Strangers Dynamic SS 1,334 14,976 Dynamic ROP SS Opt. 12,570 22,350 ROP Opt. - 2,000 4,000 6,000 8,000 10,000 12,000 14,000 16,000 18,000 20,000 22,000 24,000 Jan-09 Feb-09 Mar-09 Apr-09 May-09 Jun-09 Jul-09 Aug-09 Sep-09 Oct-09 Nov-09 Dec-09 FG Dynamic SS & ROP vs. Optimization Formula Runners Repeaters Strangers X1 X2 X3 X4 X5 Service Level Z S.S Qty DOH S.S Qty DOH S.S Qty DOH S.S Qty DOH S.S Qty DOH 90% 1.282 3,345 8.78 2,258 5.1 1,227 10.5 357 15.2 334 39.1 91% 1.341 3,500 9.19 2,362 5.4 1,284 11.0 361 15.3 349 40.9 92% 1.405 3,668 9.63 2,475 5.6 1,346 11.5 365 15.5 366 42.9 93% 1.476 3,852 10.11 2,600 5.9 1,413 12.1 369 15.7 385 45.0 94% 1.555 4,059 10.65 2,739 6.2 1,489 12.7 373 15.8 405 47.4 95% 1.645 4,294 11.27 2,898 6.6 1,575 13.5 377 16.0 429 50.2 96% 1.751 4,570 12.00 3,084 7.0 1,677 14.3 381 16.2 456 53.4 97% 1.881 4,910 12.89 3,313 7.5 1,801 15.4 385 16.4 490 57.4 98% 2.054 5,361 14.07 3,618 8.2 1,967 16.8 389 16.5 535 62.7 99% 2.326 6,073 15.94 4,098 9.3 2,228 19.0 393 16.7 606 71.0 Total Material Analysis Finished Goods Dynamic Safety Stock Combined Analysis of Raw Material Finished Goods Analysis C O D E P A R T N A M Lead Time R Type Z C.V S.S Qty S.S Days Company S.S Days Company S.S QTY Saving in Days Saving s Units Saving value 348624181 X1 10 Repeater 0.842 0.317 1382 15 8 758 -7 -623 -21945 346135211 X2 10 RUNNER 1.645 0.159 14 5 30 96 25 81 9287 813617401 X3 10 RUNNER 1.645 0.268 4281 8 10 5602 2 1320 32560 124029949 X4 90 RUNNER 1.645 0.194 1019 17 30 1846 13 827 30983 124018205 X5 90 RUNNER 1.645 0.195 2044 17 30 3686 13 1642 45343 111111111/B X6 79 RUNNER 1.645 0.201 101414 16 21 132075 5 30661 182431 348623891 X7 109 Stranger 0.126 1.662 89 12 30 223 18 134 2442 348623880 X8 109 RUNNER 1.645 0.271 10693 25 30 12594 5 1901 31993 \ Management & Development Center