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Best Regards, Bill Stankiewicz Vice President and General Manager Shippers Warehouse of Georgia Office: 678-364-3475 [email protected] http://www.linkedin.com/in/billstankiewicz2006http://www.slideshare.net/BillStankiewicz.http://www.twitter.com/BillStankiewicz Sustainable Consumer Packaged Goods member CPG Branding and Forum MemberPlease consider the environment before printing this e-mail“Change doesn\'t start on the surface. It\'s generated from consciousness.”Deepak Choprahttp://bill-stankiewicz.blogspot.com/2009/07/shippers-warehouse-in-top-70-food.htmlhttp://ask.depaul.edu/Students/MentoringandAdvice/ASK_Away_Archive.aspTRANSCRIPT
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Eye For Transport AmsterdamSeptember 27th, 2007
WorkshopReverse Logisticsin the hi-tech & electronics
industry
www.vil.be
© Flanders Institute for LogisticsJordaenskaai 25
B-2000 AntwerpenBelgium
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Flanders Institute for Logistics (VIL)
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
What is reverse logistics?
� The reverse logistics process covers the return flow of materialsfrom end customer towards manufacturing site:
� Physical flow
� Admin flow
� Financial flow
� Reverse flows are characterized by their extremely variable nature:
� Volume
� Quality
� Quantity
� Value
� Throughput times
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
RL trends in hi-tech/electronics
� Time is money: very fast devaluation of products
� Trend towards pan-European or global service networks
� Huge potential for 3PL’s
� Use of RMA (capture each return asap in the process)
� High importance of ICT for sorting /routing / SLA management
/ customer contact
� High percentage “no trouble found” (up to 40%)
� Return policy is essential (gatekeeping/filter the influx)
� Technical product knowledge needed from 3PL (e.g. I-Pod)
� B2B: credit check is important part of the process
� Reverse logistics and after sales are becoming profit centers
� Etc…
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Is this your company?
� Our customers are returning too many products!
� Our “no fault found” rate is 40%!
� We have too many intercompany returns!
� We neve see any credit from our OEM suppliers!
� Our salesforce isn’t playing by the rules!
� There is no transparency - We have no information or reports!
� Our returns situation is an accounting nightmare!
� Our returns process will always be out of
control – Let’s accept this as a fact of life…?
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Methodology: DMAIC (Six Sigma)
1) Define
2) Measure
3) Analyse
4) Improve
5) Control
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Define: perception of unimportance
(no process owner)
“The returned-goods dock of a warehouse is a window
to mistakes in engineering, sales, manufacturing and logistics.”
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Measure: returns from end customers
2.42%
4.77% 4.77%
1.92%
1.17%
0.00%
1.00%
2.00%
3.00%
4.00%
5.00%
6.00%
CI GS IN HE NDT
BG
% o
f tu
rno
ve
r
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
BE60 NL60 LU60 BENELUX GB60 DK60 IT60 ES60 PT60 IBERIA NO60 SE60 FI60 NORDIC
CI
GS
HE
TOT
End customers are returning 3-6 % of total turnover and orderlines
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Measure: return reasons
0
10
20
30
40
50
60
Transport
damage
Not happy
with product
Delivery error Quality defect Cancellation
of sale
No reason Late delivery Bad FC &
overstock
Return after
use
Commercial
Return reason
% o
f c
om
pa
nie
s
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Analyse: return value as % of turnover
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Analyse: share of RL in total logistics workload
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Analyse: detailed process map (IDEF0)
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Analyse: returns pipeline (Pareto)Pareto Analysis of Return Orders
0,00%
10,00%
20,00%
30,00%
40,00%
50,00%
60,00%
70,00%
80,00%
90,00%
100,00%
Cum. % of Return Orders
Cu
m.
Re
turn
Va
lue
Exactly 20% of return orders
account for 80% of total
return value
80% of return orders account
for 20% of total return value
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Analyse: time-stamp analysis
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Analyse: root causes (Ishikawa)
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Improve: take action
� Combat “no fault found”
� Separate RC from DC
� Select and measure necessary KPI’s
� Publish monthly return reports
� Educate salesforce and customers
� Gatekeeping / reduce the influx (return policy - RMA)
� Document returns (photos)
� Interface different ICT systems
� Correct master + data (I/C pricing)
� Automatic accounting procedures (write-off)
� Organizational discipline: prevent problems at the source
� It’s not rocket science! (e.g call center headsets)
� Etc…
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Control: elements of a total RL make-over
company/
product
infrastructure
legislation/
rules
process/
flows
product
HR/skills
systems/
KPIcost model
partners
transport
packaging
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Checklist product� High value density
� Serrato category
� Volume & weight
� Warehouse space needed (#pallet places)
� Seasonality (Christmas) -> forecasting?
� Statistics (MTBF)
� LT service contracts: B2B slow movers/spare parts needed (often >10 years)
� Top-5 return reasons (incl. no fault found!)
� Technical porduct knowledge needed
� High specialisation: “lock-in” of customer
� Inventarize 2nd hand/grey channels
� Play the recycling market (gold, silver)
� Risk management:
� Theft
� Environment (e.g. batteries)
� Fast product depreciation
� Cannibalisation (e.g. ink cartridges)
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Checklist infrastructure (warehouse)
� Keep “clean” and “dirty” flows separate: brownfield or greenfield ERC?
� # inbound docks > # outbound docks
� Automation potential is low
� Low and wide racks (manual picking, lots of buffer inventory)
� Use mezzanines (lots of slow movers/high value density/spare parts)
� Large reception area: FIFO per country/product
� Repackaging area
� Scattered desks & PC-islands (inspection/testing)
� Separate inventory areas for phase-outs & spare parts (slow movers), packaging, refurbished items, swap stock
� Separate guarded area for scrapping/shredding (containers)
� Theft risk: fencing, badge access, CCTV, night guards, “Fort Knox” area for refurbished items
� ERC economies of scale/consolidation potential: high
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Checklist ICT/KPI’s/reporting
� Identify KPI’s and collect historical data:
� # returns/product
� # returns/return reason
� # returns/customer
� Return rate/country
� Credit note amount
� Re-return rate
� # returns processed/day
� Cost/returned item
� Document throughput times (time stamps/SLA’s)
� Visibility of flows (web-enabled tracking & tracing)
� Open systems: interface/integrate with customer ERP (B2B)
� Call center: SLA contract management software needed
� Develop in-house ICT competente <-> find an ICT partner
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Checklist HR/skills
� Seasonality/peak loads: enable flex work
� Product training & technical skills (e.g. I-Pod)
� FTE admin/floor ratio: ca. 1/3
� Responsibility & accuracy (sorting/routing/scrap decisions)
� Knowledge of languages (RMA - English, French, German)
� ICT skills (SAP, Excel, Outlook)
� Procedural accuracy
� Dexterity, concentration, sharp eyesight
� Routine activities: socially beneficial employment (e.g. scrapping of ink cartridges)
� Job enrichment for outbound warehouse employees
� “Is reverse logistics female ?”
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Checklist rules/legislation
� WEEE
� Recupel: volumes reporting
� Vlarem II: limits the volume of “scrap inventory” allowed
� Shredding: OVAM + tax certification
� Sarbanes-Oxley: valuation of refurbished inventory
� ISO14001 (environmental compliance)
� TL9000 (B2B telecom)
� ISO 18000: health & safety (dangerous compounds)
� Customs and export (crossing EU borders)
� Pallet fumigation (USA/ASPAC)
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
VIL maturity model for RL: where are you?
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
Questions?
A complete VIL research report with
3PL roadmap for action
will be available in the fall of 2007.
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www.vil.be
ReverseLogistics
Workshop
VIL © 2007
www.vil.be
© All Rights Reserved
Flanders Institute for Logistics (VIL)Jordaenskaai 25
B-2000 Antwerpen (Belgium)T: +32 (0) 3 229 05 00F: +32 (0) 3 229 05 10