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Profitably Addressing Complexity in
Manufacturing
JDA Manufacturing Planning
Increasing Complexity Proves
Problematic for Manufacturers
Challenges and Opportunities
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
New Levels of Complexity Further
Threaten Profit / Satisfaction
Customer
Empowerment
Globalization
External FactorsExpanding
Network
• Choice / Option
• Expectation
• Service Level
• Now
• Shift from Regional
• Disparate Views
• Varying Local
Parameters
• Emerging Markets
• Outsourcing
• External Partners
• Shifting Reliance
• Geopolitical /
Natural Disaster
• Economic
Uncertainty
• Cost Volatility
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Product Proliferation:
Consumers Drive Choice
100%
Number of derivatives of a new car
model has increased
20%
Source: McKinsey
Average product cycle for a new
model has fallen
From 2002 to 2011
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Manufacturers Turn to Choice:
SKU Counts are Increasing
Number of SKUs in
Grocery grew
50%
between 2003 and
2010.
Source: Food Marketing
Institute
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Shifts in Supply and Delivery
Factors
Skilled Labor Shortage
40 million by 2020
Source: McKinsey
Commodity Price Increases
Raw Materials by 50%
Source: McKinsey
Transportation & Energy Costs
“Changing the Math”
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Going Global:
Accelerating Quickly
Global trade has accelerated twice as
fast as US GDP for the past 20 yearsSource: McKinsey
2/3 of surveyed high tech companies have
presence in emerging markets.
Source: IDC
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Symptoms of Failing to Manage
Complexity
“I’m not meeting service levels targets,
and I don’t see how they can improve.”
“Our plans are so inflexible that it’s always
a major disruption and margin hit to take
advantage of a new opportunity or react
to problems.”
“My operating and expediting costs are
increasing, and it’s not as simple as
passing the cost on to customers.”
“Achieving my production goal isn’t
helping me achieve my sales goal.”
“My inventory is growing.”
“My topline revenue isn’t growing.”
“I’m drowning in spreadsheets.”
“My stakeholders are demanding more.”
“I think these are my problems, but I’m not
sure.”
“I’m not meeting service levels targets,
and I don’t see how they can improve.”
“Our plans are so inflexible that it’s always
a major disruption and margin hit to take
advantage of a new opportunity or react
to problems.”
“My operating and expediting costs are
increasing, and it’s not as simple as
passing the cost on to customers.”
“Achieving my production goal isn’t
helping me achieve my sales goal.”
“My inventory is growing.”
“My topline revenue isn’t growing.”
“I’m drowning in spreadsheets.”
“My stakeholders are demanding more.”
“I think these are my problems, but I’m not
sure.”
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Symptoms of Failing to Manage
Complexity
Results of Failing to Manage Complexity
Customer dissatisfaction
Missed opportunities
Competing goals / incentives
Stagnant growth / margin decline
Excess inventory and carrying costs
Misallocated resources and assets
Productivity drain / data challenges
Unhappy stockholders / leadership
Compromised enterprise visibility
Compromised decision-making
Compromised timelines
Compromised accuracy
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Manufacturing Must Shift
Inward-Focused
One-Size-Fits-All Structure
Lacked Flexibility
Misaligned Functions
Locally Optimized
Customer-Centric
Segmented to Serve Different
Markets
Business Agility
Internal and External
Synchronization
Globally Optimized for
Performance
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
JDA Manufacturing Planning Suite
Profitably Addressing Complexity
EXECUTION
Inventory
Planning
Factory
Planning
Master
Planning
Demand
Planning
JDA
Manufacturing
Planning
Sales & Operations Planning
STRATEGY
Process & People
Strategy and Process
Organizational Design
Change Leadership
Continuous Improvement
Access & Delivery
JDA Cloud
Business Agility
Sustainable ROI
Upgrade & Optimization
Orchestrating
manufacturing
and distribution
operations …
by aligning
universal and
segmented
demand …
with resources,
materials, and
assets …
to optimize buy-
make-move-
store-deliver
decisions …
across the
enterprise.
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Problem Solved:
Customer-Centric Supply Chain
Scrambling to Adapt to Forecast Misfires
Low Ability to Detect Market Changes
Lack of Forecasting Depth
Compromised Service Levels
BEFORE JDA
Manufacturing Planning
Earlier Identification of Market Changes
Improved Forecast Accuracy
Ability to Plan at Lower Levels
Better Service Level
AFTER JDA
Manufacturing Planning
Underperforming Forecasts | Low Loyalty Improved Customer Understanding | Higher Loyalty
Increased customer service rating
to 99.5% while reducing inventory
17%
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Problem Solved:
Segmented Supply Chain
One-Size-Fits-All Approach to Customers
Lack of Ability to Align Business Goals
Compromised Profitability
Boilerplate Offerings
BEFORE JDA
Manufacturing Planning
Differentiated Service by Customer
Improved Business Goal Alignment
Improved Order Prioritization
Segmented Demand View
Improved Profitability
AFTER JDA
Manufacturing Planning
Standard Offerings | One-Size-Fits-All Customer View Customized Approaches | Improved Profitability
Grew stronger connections to
customers, reduced cost /
complexity, improved internal
collaboration and forecasting..
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Problem Solved:
Profitable & Agile Supply Chain
Limited View into Global Enterprise
Sluggish Planning Integration
Long Response Cycles
Inflexible Processes
BEFORE JDA
Manufacturing Planning
Comprehensive Enterprise Information
Ability to Reconfigure Supply Chain
Agility and Quick Responses
Supply / Demand Cohesion
Improved Profitability
AFTER JDA
Manufacturing Planning
Siloed Functions | Sluggish Turnarounds Improved Responsiveness | New Opportunities
Doubled inventory turns; Enabled
rapid response to dynamic market
conditions
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Problem Solved:
Synchronized Supply Chain
Alignment of Supply, Demand, Finance, Etc.
Greater Flexibility and Response Time
Improved Asset/Resource Utilization
Scenario-Based Decision Support
Improved Agility
AFTER JDA
Manufacturing Planning
Failure to Bridge Strategy and Execution
Inaccurate Order Promising
Compromised Service Levels
Lack of Decision Support
Waste of Assets
BEFORE JDA
Manufacturing Planning
Guesswork | Failure to Adapt and Execute Supply Chain Responsiveness | Profitability
Centralized planning into one process;
Cut forecast lead time from 4 weeks to
2 weeks, reducing planning effort by
30%, errors by 90%
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Problem Solved:
Optimized Supply Chain
Improved Utilization of Assets, Inventory, etc.
Improved ROI / Time-to-Value
Reduced Excess Inventory
Improved Service Levels
AFTER JDA
Manufacturing Planning
Hidden Opportunities for Improvement
Compromised Service Levels
Expensive Miscalculations
Flat Metrics
BEFORE JDA
Manufacturing Planning
Missed Opportunity for Higher Investment Return Maximized Margin | Improved Customer Satisfaction
Decreased inventory by 50%
Increased on-time deliveries 90%
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
JDA Manufacturing Planning:
End-to-End
“JDA has enabled us to
actually take market
share by being able to
deliver product on
time.”
Fujitsu Network
Communications
ONLY
High Value Functionality • High Adoption • Greater Productivity
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
20-25% Forecast Accuracy
55-94% Order Promising Accuracy
5-8% Inventory Turns
11% Production Line Efficiency
.5-5% Service Level Improvement
42% Planning Effort Reduction
4-15% Safety Stock Reduction
4-8% Overall Inventory Reduction
5-12% Lost Sales Reduction
JDA Manufacturing Planning:
Agile, Aligned, Optimized
Optimizing Opportunities for Growth
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Putting an End to an
Impossible Choice
PROFIT SATISFACTION
• Tighter integration of strategy to plan to execution
• Improved alignment of investments with returns
• Increased efficiencies and cost savings
• Decisions supported with dynamic scenarios
• Decreased inventory
• Tighter integration of strategy to plan to execution
• Improved alignment of investments with returns
• Increased efficiencies and cost savings
• Decisions supported with dynamic scenarios
• Decreased inventory
• Improved OTIF
• Greater agility in responding to changes
• Priorities based on segmentation
• Global and expanded network resources
available to meet customer expectations
• Improved OTIF
• Greater agility in responding to changes
• Priorities based on segmentation
• Global and expanded network resources
available to meet customer expectations
ONLY
+
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Guiding the Industry’s Leading
Supply Chains
500+
38+
Manufacturers
Countries
Image courtesy: alpha
20 of Gartner Top
25 Supply Chains
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
Optimizing Manufacturing Across the
Enterprise
Demand Planning
Sales & Operations Planning
Master Planning
Factory Planning
Inventory Planning
ONLY
Profitability • Customer Satisfaction • Alignment • Agility
Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL
http://www.jda.com/solutions/manufacturing-planning/
Discover More about JDA
Manufacturing Planning

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Profitably Addressing Complexity in Manufacturing

  • 1. Profitably Addressing Complexity in Manufacturing JDA Manufacturing Planning
  • 2. Increasing Complexity Proves Problematic for Manufacturers Challenges and Opportunities
  • 3. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL New Levels of Complexity Further Threaten Profit / Satisfaction Customer Empowerment Globalization External FactorsExpanding Network • Choice / Option • Expectation • Service Level • Now • Shift from Regional • Disparate Views • Varying Local Parameters • Emerging Markets • Outsourcing • External Partners • Shifting Reliance • Geopolitical / Natural Disaster • Economic Uncertainty • Cost Volatility
  • 4. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Product Proliferation: Consumers Drive Choice 100% Number of derivatives of a new car model has increased 20% Source: McKinsey Average product cycle for a new model has fallen From 2002 to 2011
  • 5. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Manufacturers Turn to Choice: SKU Counts are Increasing Number of SKUs in Grocery grew 50% between 2003 and 2010. Source: Food Marketing Institute
  • 6. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Shifts in Supply and Delivery Factors Skilled Labor Shortage 40 million by 2020 Source: McKinsey Commodity Price Increases Raw Materials by 50% Source: McKinsey Transportation & Energy Costs “Changing the Math”
  • 7. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Going Global: Accelerating Quickly Global trade has accelerated twice as fast as US GDP for the past 20 yearsSource: McKinsey 2/3 of surveyed high tech companies have presence in emerging markets. Source: IDC
  • 8. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Symptoms of Failing to Manage Complexity “I’m not meeting service levels targets, and I don’t see how they can improve.” “Our plans are so inflexible that it’s always a major disruption and margin hit to take advantage of a new opportunity or react to problems.” “My operating and expediting costs are increasing, and it’s not as simple as passing the cost on to customers.” “Achieving my production goal isn’t helping me achieve my sales goal.” “My inventory is growing.” “My topline revenue isn’t growing.” “I’m drowning in spreadsheets.” “My stakeholders are demanding more.” “I think these are my problems, but I’m not sure.” “I’m not meeting service levels targets, and I don’t see how they can improve.” “Our plans are so inflexible that it’s always a major disruption and margin hit to take advantage of a new opportunity or react to problems.” “My operating and expediting costs are increasing, and it’s not as simple as passing the cost on to customers.” “Achieving my production goal isn’t helping me achieve my sales goal.” “My inventory is growing.” “My topline revenue isn’t growing.” “I’m drowning in spreadsheets.” “My stakeholders are demanding more.” “I think these are my problems, but I’m not sure.”
  • 9. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Symptoms of Failing to Manage Complexity Results of Failing to Manage Complexity Customer dissatisfaction Missed opportunities Competing goals / incentives Stagnant growth / margin decline Excess inventory and carrying costs Misallocated resources and assets Productivity drain / data challenges Unhappy stockholders / leadership Compromised enterprise visibility Compromised decision-making Compromised timelines Compromised accuracy
  • 10. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Manufacturing Must Shift Inward-Focused One-Size-Fits-All Structure Lacked Flexibility Misaligned Functions Locally Optimized Customer-Centric Segmented to Serve Different Markets Business Agility Internal and External Synchronization Globally Optimized for Performance
  • 11. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL JDA Manufacturing Planning Suite Profitably Addressing Complexity EXECUTION Inventory Planning Factory Planning Master Planning Demand Planning JDA Manufacturing Planning Sales & Operations Planning STRATEGY Process & People Strategy and Process Organizational Design Change Leadership Continuous Improvement Access & Delivery JDA Cloud Business Agility Sustainable ROI Upgrade & Optimization Orchestrating manufacturing and distribution operations … by aligning universal and segmented demand … with resources, materials, and assets … to optimize buy- make-move- store-deliver decisions … across the enterprise.
  • 12. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Problem Solved: Customer-Centric Supply Chain Scrambling to Adapt to Forecast Misfires Low Ability to Detect Market Changes Lack of Forecasting Depth Compromised Service Levels BEFORE JDA Manufacturing Planning Earlier Identification of Market Changes Improved Forecast Accuracy Ability to Plan at Lower Levels Better Service Level AFTER JDA Manufacturing Planning Underperforming Forecasts | Low Loyalty Improved Customer Understanding | Higher Loyalty Increased customer service rating to 99.5% while reducing inventory 17%
  • 13. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Problem Solved: Segmented Supply Chain One-Size-Fits-All Approach to Customers Lack of Ability to Align Business Goals Compromised Profitability Boilerplate Offerings BEFORE JDA Manufacturing Planning Differentiated Service by Customer Improved Business Goal Alignment Improved Order Prioritization Segmented Demand View Improved Profitability AFTER JDA Manufacturing Planning Standard Offerings | One-Size-Fits-All Customer View Customized Approaches | Improved Profitability Grew stronger connections to customers, reduced cost / complexity, improved internal collaboration and forecasting..
  • 14. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Problem Solved: Profitable & Agile Supply Chain Limited View into Global Enterprise Sluggish Planning Integration Long Response Cycles Inflexible Processes BEFORE JDA Manufacturing Planning Comprehensive Enterprise Information Ability to Reconfigure Supply Chain Agility and Quick Responses Supply / Demand Cohesion Improved Profitability AFTER JDA Manufacturing Planning Siloed Functions | Sluggish Turnarounds Improved Responsiveness | New Opportunities Doubled inventory turns; Enabled rapid response to dynamic market conditions
  • 15. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Problem Solved: Synchronized Supply Chain Alignment of Supply, Demand, Finance, Etc. Greater Flexibility and Response Time Improved Asset/Resource Utilization Scenario-Based Decision Support Improved Agility AFTER JDA Manufacturing Planning Failure to Bridge Strategy and Execution Inaccurate Order Promising Compromised Service Levels Lack of Decision Support Waste of Assets BEFORE JDA Manufacturing Planning Guesswork | Failure to Adapt and Execute Supply Chain Responsiveness | Profitability Centralized planning into one process; Cut forecast lead time from 4 weeks to 2 weeks, reducing planning effort by 30%, errors by 90%
  • 16. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Problem Solved: Optimized Supply Chain Improved Utilization of Assets, Inventory, etc. Improved ROI / Time-to-Value Reduced Excess Inventory Improved Service Levels AFTER JDA Manufacturing Planning Hidden Opportunities for Improvement Compromised Service Levels Expensive Miscalculations Flat Metrics BEFORE JDA Manufacturing Planning Missed Opportunity for Higher Investment Return Maximized Margin | Improved Customer Satisfaction Decreased inventory by 50% Increased on-time deliveries 90%
  • 17. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL JDA Manufacturing Planning: End-to-End “JDA has enabled us to actually take market share by being able to deliver product on time.” Fujitsu Network Communications ONLY High Value Functionality • High Adoption • Greater Productivity
  • 18. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL 20-25% Forecast Accuracy 55-94% Order Promising Accuracy 5-8% Inventory Turns 11% Production Line Efficiency .5-5% Service Level Improvement 42% Planning Effort Reduction 4-15% Safety Stock Reduction 4-8% Overall Inventory Reduction 5-12% Lost Sales Reduction JDA Manufacturing Planning: Agile, Aligned, Optimized Optimizing Opportunities for Growth
  • 19. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Putting an End to an Impossible Choice PROFIT SATISFACTION • Tighter integration of strategy to plan to execution • Improved alignment of investments with returns • Increased efficiencies and cost savings • Decisions supported with dynamic scenarios • Decreased inventory • Tighter integration of strategy to plan to execution • Improved alignment of investments with returns • Increased efficiencies and cost savings • Decisions supported with dynamic scenarios • Decreased inventory • Improved OTIF • Greater agility in responding to changes • Priorities based on segmentation • Global and expanded network resources available to meet customer expectations • Improved OTIF • Greater agility in responding to changes • Priorities based on segmentation • Global and expanded network resources available to meet customer expectations ONLY +
  • 20. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Guiding the Industry’s Leading Supply Chains 500+ 38+ Manufacturers Countries Image courtesy: alpha 20 of Gartner Top 25 Supply Chains
  • 21. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL Optimizing Manufacturing Across the Enterprise Demand Planning Sales & Operations Planning Master Planning Factory Planning Inventory Planning ONLY Profitability • Customer Satisfaction • Alignment • Agility
  • 22. Copyright 2014 JDA Software Group, Inc. - CONFIDENTIAL http://www.jda.com/solutions/manufacturing-planning/ Discover More about JDA Manufacturing Planning