Exel managing the supply chain for globally integrated products

Today many of the products that we consume have been brought to us through globally integrated distribution systems. Examples are the fruit and vegetables tn our local supermarket, which arrive fresh from all over the world, and cars containing components from many different countries. We tend to take the delivery of these products for granted without realising the real complexity of the planning that is involved in making sure, that for example, all of the components for a modern VW Beetle arrive at their final assembly point at ust the right time. This case study introduces you to some of the processes that go on behind the scenes by examining supply chain management. Supply chain management re!uires specialist skills and is all about efficiently bringing together all links and stages involved in creating a high !uality supply chain. Exel provides services to a wide range of manufacturing and retailing industries. Exel"s range of logistics solutions encompasses the complete supply chain from design and consulting through freight forwarding, warehousing and distribution services to integrated information management and e#commerce. Exel now has contract logistics operations in $% countries as well as &reight 'anagement activities that cover over %() countries. *n the automotive industry, +ust#*n#Time and ,ean -roduction systems are essential.
Just-in-time and lean production

+ust#*n#Time .+*T/ is a very simple idea but one that is essential in modern supply chain management. +*T sets out to cut costs by reducing the amount of goods and materials a firm holds in stock. +*T involves0 producing and delivering finished goods 1 ust in time" to be sold partly finished goods 1 ust in time" to be assembled into finished goods parts 1 ust in time" to go into partly finished goods materials 1 ust in time" to be made into parts.

The principle that underpins +*T is that production should be 1pulled through" rather than 1pushed through". This means that production should be for specific customer orders, so that the production cycle starts only once a customer has placed an order with the producer. 2tocks are delivered when they are needed. 3onse!uently, this approach re!uires much more fre!uent delivery of stocks. 4eveloping a +*T approach re!uires sophisticated planning and considerable experience in this field. +ust#*n#Time is the key element in what is termed lean production. ,ean production is a philosophy and a way of working involving eliminating all forms of waste .where waste is defined as anything that does not add value in the production process and supply chain/. The idea behind lean production stems from +apan where for many years supply chain managers have been trying to eliminate 1muda" 5 any activity which involves wasted effort, materials and time.

6 further advantage of +*T is the benefit derived from eliminating lineside storage of parts and the associated 7clutter8 which inhibits efficient movements to9from the production line. By reducing the storage of parts at the production line, a manufacturer is often able to increase the speed of the production line and produce more cars with the same number of resources, lowering the overall unit cost of production.
Helping Volkswagen to transfer its JIT system from Spain to Mexico

:ne of the best examples of modern supply chain management is in motor vehicle manufacturing. 'odern cars are an example of global products containing research and design features which involve the collaboration of many people from many nations. The components that go into the final assembly are likely to be produced in many separate locations and involve a range of assembly and subassembly activities. Take the VW Beetle, for example. Traditionally a ;erman product, a lot of VW models are produced today in <orth and 2outh 6merica, taking advantage of a pool of skilled labour in countries like 'exico and Bra=il 5 and with ready access to the lucrative >nited 2tates market. The challenge for supply chain management When Volkswagen decided to produce its new Beetle model, the goal was to transfer the lean manufacturing techni!ue and highly effective ust#in#time supplier park model from the VW92E6T assembly plant in 'artorell in 2pain, to -uebla in 'exico. 2upplier parks are often found in the car industry where an assembly plant , warehousing facilities, various suppliers and manufacturers as well as third#party logistics providers are located close together. This can reduce transport time to a few minutes. The solution Exel has worked with car manufacturers to develop a park system of managing end operations of the supply chain for motor vehicle assembly. 'any of the key end component suppliers are located close to the final assembly point. Exel has created and manages the +*T system that ensures a smooth running supply chain of parts to the new Beetle final assembly plant which eliminates waste from the process. Volkswagen collaborated with Exel, which designed, engineered and now operates the -ark in 2pain, to transfer the park model to 'exico. The 2upplier *ndustrial -ark in 2pain was created near the factory and now includes $? suppliers. 2ubassembly activities are carried out at the -ark, guaranteeing +*T delivery and =ero stocks at final assembly lines. Exel is responsible for primary transport from the component suppliers" main plants to the -ark. The company is also responsible for warehousing, picking, subassembly and se!uencing operations, and deliveries to the assembly lines. When new deliveries are re!uired for assembling the cars messages are communicated from the plant by E4* .Electronic 4ata *nterchange/ giving Exel sometimes only %)? minutes to notify suppliers and prepare and deliver subassemblies to the final assembly line. The Exel +*T se!uencing operation is the cornerstone of the supplier industrial park that serves the Volkswagen assembly plant. The results 6dopting the supplier park model in 'exico has helped VW to reach its present level of %,$@) vehicles per day. Exel is providing supply chain services not only for the new Beetle, but also for

the 6A, a redesigned +etta and also the ;olf models. 6s an experienced logistics leader, operating globally, Exel has an established infrastructure in 'exico, servicing clients such as -rocter B ;amble and 4aimler3hrysler. Cowever, Exel had to virtually start from scratch to staff the supplier park in -uebla. *t created a team of skilled and experienced managers from 'exico, 6merica and Europe, and hired line workers and se!uencing personnel from the -uebla area who were provided with intensive training. Exel employs around @?) people at the -uebla facility. Conclusion 2upply chain management is an important area of study. 2pecialist companies are able to save businesses large amounts of money, time and effort by creating an effective supply chain. The next time you see a new VW Beetle you will be better able to appreciate that the high !uality of the product and its value for money are not only a result of high !uality design and engineering, but also a direct result of lean production, ust#in#time methods and premium supply chain management.