yves kerstens, vice president logistics & supply chain management
DESCRIPTION
Yves Kerstens, Vice President Logistics & Supply Chain Management Supply-Chain Council European Conference, 11 October 2007. Global Organisation Bridgestone. Bridgestone Corporation Head Office: Tokyo, Japan. Bridgestone America Holding Regional HQ in Nashville, USA. - PowerPoint PPT PresentationTRANSCRIPT
Yves Kerstens, Vice President Logistics & Supply Chain Management
Supply-Chain Council European Conference, 11 October 2007
Bridgestone Corporation
Head Office: Tokyo, Japan
Bridgestone America Holding
Regional HQ in Nashville, USA
Bridgestone Europe NV/SA
Regional HQ in Brussels
4 technical centres Tokyo, Japan (2), Rome, Italy & Akron, USA
57 tyre factories worldwide
98 plants for other products
Sales network in more than 150 nations and territories around the world
2006 Key Data:
Employees, worldwide 123,000
Consolidated subs 440 companies
Financial results 25,1 billion US$
Net earnings 714 million US$
Global Organisation Bridgestone
Tyres
(80 % of our total activity) Passenger cars and recreational
vehicles Trucks and buses, heavy and light Commercial vans Agriculture Off-the-road vehicles Motorcycles and scooters Aircraft Subways and monorails Racing, go-karts, motorcycles and
scooters
Activities and Products
Tyre Market Sales - Evolution 1986 – 2005
13 46514 800
16 750
18 333
13 751
6 000
16 150
17 888 17 920
12 300
6 800
13 600
15 150
17 500
6 100
4 796
1 700
5 6006 350
2 6932 000
3 2554 043 4 513
2 717
2 200
2 922 3 1503 616
0
2 000
4 000
6 000
8 000
10 000
12 000
14 000
16 000
18 000
86 88 90 92 94 96 98 99 01 02 03 04 05 06
Bridgestone Michelin Goodyear Continental Pirelli Sumitomo
Millions of US dollars - Source: Tire Business, August 28, 2006
Passenger Car Tyres: Original Equipment Market
Bridgestone basically supplies tyres to all mass market manufacturers in
the world 11,60511,691
13,12913,518 15,249 15,332
15,23815,759 16,687
16,806 17,231
12.9% 13.5%15.0%
15.4%
20.0%19.6%19.3%18.3%18.2%18.2%17.9%
0
2,000
4,000
6,000
8,000
10,000
12,000
14,000
16,000
18,000
20,000
2001 2002 2003 2004 2005 2006 2007 Est 2008 LTP 2009 LTP 2010 LTP 2011 LTP
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
Bridgestone evolution in the European OE market
Passenger Car Tyres: Replacement Market
For the replacement market, Bridgestone Europe produces tyres for small city cars up to exclusive super cars. Tyres are sold through retail channels such as: tyre dealers,
auto centres, gas stations, hyper markets and car dealers.
Bridgestone Europe has a market share of around 13% in Europe with a target to reach 15% by 2008.
Bridgestone Europe sells mainly following brands: Bridgestone, Firestone and Dayton, following the multibrand strategy: good-better-best.
A Network structure in line with market requirements, competitors and new European environment
European Borders are fading, supporting cross border business flows
Central control of Finished Goods inventory to improve customer service
Provide a consistent 24 hours service to almost 95 % of the customers in Europe
Implementation of Pan-European strategies in the area of warehousing and distribution resulting in a lower cost base
Consistent measurement of our integrated performance to be able to benchmark and define improvements
A European LSCM organization with people acting on a central, regional and local base
Business plan objectives Customer Service improvements Reduction of Cost To Serve (-10 %) Functional Excellence and
Organisational Synergies Reduced Asset Base and Working
Capital
Minimise costs
Gain Competitive Advantage
ProducesIntegrates supply chain & delivers
Sells & defines
customer needs
Economies of Scale
Differentiation Customer
Focus
Customer Service
Cost to serve
MANUFACTURING
PLANTS
SALES
CUSTOMERS
BSEU LSCM
PLANT
WHS
DISTRIBUTION
WHS
The Supply Chain Management Policy
Our Supply Chain Vision The supply chain division writes the music, directs the
orchestra, but has some musicians being employed by third parties
One of the major drivers: the increasing affordable accessibility of information and communication technology (ICT) that enables the execution of the supply chain
Bridgestone
The How ?
Working Smarter: Process optimalisation Operational excellence Continuous Improvements Standardization
Working Cheaper: Cost optimalisation Creation of Center of Excellences Outsourcing to create synergies Virtual organization
Working Bigger: Scale optimalisation Organic growth Shared operations
Drivers for outsourcing operations and business processes Create visibility and control over service levels and costs Support a flexible network structure to adapt changes in the markets -Variable cost
base Cost reduction via more efficient operations (use 3PL experience/buying power) Lack of local experience Focus on core activities Standardization
Outsourcing components Transport (FTL) Distribution (Milk runs) Warehousing operations Real estate Warehouse & Transportation Systems Planning – Control tower (Track & trace) Invoice control Contract management Inventory management
The How?
Strategy is to outsource operations but keep limited number in-sourced to keep operational experience and internal benchmarking possibilities
Context
Carriers consolidation in Europe (2004-2007)
Central negotiations and standard contracts in place
Ownership of all transportation contracts shifted to BSEU
Compliance follow-up needed (Maverick spend)
Organisation of invoice verification, booking and payment needed to be improved and aligned
Solution
Outsource this process to a third party with automatic control of pricing and posting of invoices into ERP
Avoid invoice duplication Reduce overbilling (2-3%) 100 % Rate check 100 % Execution check Correct accrual setting
Outsource because of Dedicated and experienced team LSCM Focus on service Timely & Accurate reporting Quality / Control / Audit Cost Reductions Visibility improved management
capabilities
Outsourcing of Freight Invoice verification
Business issues
ISSUES BENEFITS OF CENTRALISATION
Difficult to control freight costs and accruals, since automatic accruals have to be made on a line item basis
Based on agreed rates a pre-invoice is checked by the carrier and accruals are automatically uploaded in SAP
Concern that SAP posting are being made by many different people around Europe who have open access to central accounting
Limit access to central accounting as key job is outsourced, which will reduce control risksUpload invoice data electronically
Reluctance by some local operations to perform this duty, therefore we cannot guarantee that invoices are processed on an ‘accurate and timely’ basis
BSEU will pass responsibility to an independent 3rd party & free up local resources
How to control if transporters are over billing ? (we check only a % of invoices)
Potential cost savings for LSCM from stopping over billing via 100% checking and economies of scale / systems use to reduce working hours involved
Time consuming to book numerous freight invoices into SAP (+- 10.000/year)
Potentially save money from economies of scale & systems. Permit staff to focus on their ‘core’ jobs
Waste time when vendors call concerning unpaid invoices
Outsourced & centralised in 1 location where all info is available for quicker response + pro-active control of invoices as they are received
Partner selectionA B C D
Implementation process ++ +++ +++ -
Service Offered Pre-billingInvoice
MatchingInvoice
MatchingInvoice
Matching
IT Innovation +++ ++ + ?
Confidentiality +++ --- +++ +++
Maturity (Experience on the market) ++ +++ + +
Flexibility +++ ++ + -
Communication Flow +++ ++ ++ -
Business knowledge (BSEU requirements)
++ + + -
Main Business (yes=***/ no=*) Yes No No No
Audit Process (Criterias audited) +++ +++ +++ -
Issue resolution Flow +++ ++ ++ -
Continuous Improvements (proactive collaboration)
+++ ++ +++ ?
Location NL / Ukraine NL / Czech India /Europe Europe
Pricing structureTo be
negotiatedPer activity
Headcount based
Per activity
OK
ETOF
Order details
Pre - calculation& account coding
ISD
Match
Execution
Consolidationof orders
Issueresolution
ISDR
ReportingFinal
Invoice
StatementWhat 3 PL
Should invoice
Pre- invoice
Payment
No
Yes
Approved finalinvoice with
coding details
3 PL 3 PL
FSE
(1)
(1)
(2)
(2)
(3)
(4)
(5)
(6)
Integrated process of planning, execution, audit and settlement
(2)
(7)
ControlPay Process overview
Bridgestone Finance
Bridgestone LSCM
Expected Benefits Operational benefits
Central rate database management : Carriers cannot be used without approved rates 100% invoice line check including special costs like waiting times, gas oil surcharge,… Communication platform with carriers (replacing phone, fax,…) One Point of contact for our European suppliers with full traceability of issue resolution Visibility and Increased compliance Dedicated and experienced team Timely & correct accruals for month end closing
Compliance Sarbanes-Oxley (SOX) Compliance : Segregation of duties VAT will be invoiced as per agreed VAT rules as opposed to being accepted as billed by
carriers Costs Reductions
Elimination of over billing errors (double invoices, 100% rate check, execution check) Administrative tasks no longer required (no extra resources required for growth in
business) Visibility and reporting
Single location providing visibility to all parties (Carriers, BSEU, Claims, …) Improved cost allocation capabilities Share operational status visibility through Transportation Cycle
Estimate (*):
AreaConservativ
eRealistic
Optimistic
Over billing reduction €1431,850 €1879,510 €2419,750
Headcount Finance
Headcount LSCM
€307,665
€225,000
€356,625
€270,000
€405,000
€360,000
Carrier Selection Compliance €876,000 €1035,500 €1095,000
Total €2,840,515€3,641,6
35€4,279,7
50
Project is self funding after implementation cost
Initial Business Case
(*) Adapted figures
April May June July Aug Sept Oct Nov Dec JanPre
para
tion
Wave 1
Wave 2
Roll out solution to all other sites
Implementation in 3 Pilot Sites•ELC North: Zeebrugge•MDC: Poznan•RDC: France
Site Go live
Prepare Implementation
• Collect Master Data• Develop interfaces• Setup new processes• Carrier Communication
Initial Implementation Planning – 2 sessions
Findings after 1 year operations (1) Full Truck Load business is 100% operational and process is
stable For “secondary business (17 countries) ” situation is
diversified Some markets are 100% operational Still some countries are not live
• Carriers refusing to participate• Facing technical issues with some carriers
Some countries we encountered serious problems• We ended up in paying invoices twice• We had to make pre-payments to carriers• Local people initially opposed, because they lost part of their
power
Learning curve takes time (Table to be updated with YTD figures)
Findings after 1 year of operations (2) Involvement of multiple stakeholders requires strong project
management Carriers Central SCM & Local SCM Finance Invoice verification company
The local organisation needs to be prepared well Clear rules need to be established upfront and communicated Training upfront and afterwards is key The local people are not finance people Realise and foresee at startup, this is not first priority for the people
involved Exception handling is under estimated ( returns, extra costs, …)
Findings after 1 year of operations (3) The process and system prove to be very effective
systematic and full control on the invoices full visibility on the accruals for freight
After having the process effective, our current priority is to become even further efficient by becoming
more pro-active follow the progress via KPI:
Current focus areas Reviewing all new contracts from carriers by the Central Contract
Team Reviewing weekly the status by country and carrier (tracking
report ). Challenging all issues more than 5 days and ensuring that all
issues more than 25 days are closed (CP system used to monitor the issues).
Findings after 1 year of operations (4)
Business case realisation Over billing reduction is clearly achieved but difficult to
measure Headcount Finance is realised, but does not result
in headcount reduction Headcount LSCM is not realized. More focus is still required. Carrier Selection Compliance : 100% Data and accrual accuracy has improved significantly
Would we do it again ?
YES, but lessons learned :
You never communicate enough both external and internal
Thank you for your attention