An introduction to supply chain optimization

There are a lot of reasons for finding greater efficiency in a company’s supply chain. Companies may approach the process to reduce costs, some may look for increasing speed, and still others  seek to increase reliability and stability. Whatever the goal of the organization, the process of finding any of these stems from reducing opacity and analyzing data as much as it is managing parts and materials that travel through the supply chain.

Much like the many goals available, there are many ways to approach the optimization process. This page is built to help companies start the process well informed on the basics of what needs to be done and what directions they could take to get more out of their supply chains. As with all intensive and transformative processes, it’s best to start by identifying a strategy to start from.

What supply chain optimization strategies are there?

Companies have a number of strategic options to choose from. Optimization strategies encompass a wide range of approaches aimed at improving the efficiency, effectiveness, and overall performance of the supply chain network. These strategies may vary in results achieved depending on factors such as the company’s industry, internal processes, business objectives, and specific product challenges. Companies would do well to thoroughly research each method to make sure which fits best for their needs before committing to any strategic path. Here are some common supply chain optimization strategies:

1. Lean Manufacturing: Lean principles focus on eliminating waste and maximizing value-added activities in production processes. This includes reducing inventory on-hand, setting up more responsive replenishment processes, reducing cycle times, improving process flow, and enhancing overall efficiency.

2. Just-in-Time (JIT) Inventory Management: JIT is a strategy aimed at minimizing inventory holding costs by synchronizing production with customer demand. It involves producing and delivering goods only as needed, reducing excess inventory and associated carrying costs.

3. Vendor-Managed Inventory (VMI): VMI is a collaborative inventory management approach in which suppliers monitor and replenish inventory levels at customer locations based on agreed-upon criteria such as consumption rates or stock levels. This helps reduce inventory holding costs and ensures product availability.

4. Sourcing Optimization: Optimization strategies involve selecting the most efficient suppliers and sourcing locations while considering factors such as cost, quality, lead times, and risk. This may involve diversifying the supplier base, leveraging economies of scale, or adopting strategic partnerships.

5. Supplier Network Optimization: Network optimization aims to design and configure the supply chain network to minimize costs, improve service levels, and enhance responsiveness. This includes decisions related to facility location, distribution center layout, transportation routes, and mode selection.

6. Technology Adoption: Leveraging technology solutions such as Materials Requirements Planning (MRP) systems, Supply Chain Management (SCM) software, Advanced Analytics, Internet of Things (IoT), and Artificial Intelligence (AI) can streamline processes, improve decision-making, and enhance visibility across the supply chain.

7. Collaborative Planning, Forecasting, and Replenishment (CPFR): CPFR involves sharing information and collaborating with supply chain partners to jointly plan and forecast demand, align production and inventory levels, and improve overall supply chain efficiency and responsiveness.

8. Continuous Improvement (Kaizen): Embracing a culture of continuous improvement involves regularly evaluating processes, identifying inefficiencies, and implementing incremental changes to optimize supply chain performance over time.

Companies should also consider these strategies may not be mutually exclusive and could be combined or customized to address specific challenges and opportunities within their particular supply chain. By implementing a combination of these strategies and continuously refining processes, organizations could further optimize their supply chain networks to achieve greater efficiency, reduce costs, improve customer satisfaction, and gain a competitive advantage in the marketplace.

Common steps in the supply chain optimization process

Supply chain optimization is a systematic process that involves several steps aimed at improving the efficiency, effectiveness, and overall performance of the supply chain network. This means collecting data on the current process and partnering with both internal groups and vendors to learn more about the process. It also means taking what’s learned and relationships built to build a reliable and efficient solution that can be implemented in a timely manner. While specific steps may vary depending on the organization and its unique challenges, the following are common steps in the supply chain optimization process:

1. Assessment and Analysis:

• Conduct a comprehensive assessment of the current supply chain network, including processes, systems, and performance metrics.
• Analyze historical data, trends, and key performance indicators (KPIs) to identify areas of inefficiency, bottlenecks, and opportunities for improvement.

2. Define Objectives and Priorities:

• Clearly define the objectives and priorities of the supply chain optimization initiative, such as reducing costs, improving customer service, enhancing flexibility, or mitigating risks.
• Prioritize areas for optimization based on their potential impact on overall supply chain performance and alignment with business goals.

3. Modeling and Simulation:

• Develop mathematical models and simulation tools to evaluate different scenarios and assess the impact of potential changes on the supply chain network.
• Use simulation to test various strategies, such as changes in inventory levels, production schedules, transportation routes, or sourcing strategies, to identify the most effective solutions.

4. Optimization Plan Development:

• Based on the analysis and simulation results, develop a comprehensive optimization strategy that addresses identified inefficiencies and aligns with the defined objectives and priorities.
• Consider a combination of strategies and tactics, including process improvements, technology adoption, collaboration with partners, and organizational changes, to optimize the supply chain network.

5. Implementation Planning:

• Develop a detailed implementation plan outlining specific actions, timelines, responsibilities, and resource requirements for executing the new optimization strategy.
• Consider potential risks, constraints, and dependencies, and develop contingency plans to mitigate any potential disruptions during implementation.

6. Execution and Deployment:

• Implement the optimization initiatives according to the planned schedule and guidelines, ensuring effective communication, coordination, and collaboration across the organization and with supply chain partners.
• Monitor progress and performance closely, and make adjustments as needed to address any issues or deviations from the plan.

7. Performance Measurement and Monitoring:

• Establish performance metrics and key performance indicators (KPIs) to track the impact of optimization efforts on supply chain performance.
• Continuously monitor and evaluate performance against established benchmarks, and use feedback to identify further opportunities for improvement.

8. Implementing Continuous Improvement:

• Foster a culture of continuous improvement by encouraging feedback, learning from successes and failures, and identifying new opportunities for optimization.
• Regularly review and update the optimization strategy and implementation plan to adapt to changing business conditions, market dynamics, and customer requirements.

What metrics go into the supply chain optimization process?

Supply chain optimization relies on various metrics to evaluate performance, identify areas for improvement, and measure the impact of optimization efforts. These metrics span different aspects of the supply chain and provide insights into efficiency, effectiveness, and customer satisfaction. Here are some key metrics commonly used in supply chain optimization:

1. Inventory turnover: Measures how quickly stock is being sold or used over a specific period, indicating the efficiency of inventory management. It is calculated as the cost of goods sold divided by the average inventory value.

2. Order fulfillment cycle time: Measures the time it takes from receiving a customer order to delivering the product. It reflects the responsiveness and efficiency of order processing and fulfillment operations.

3. On-time delivery: Measures the percentage of orders delivered to customers within the promised delivery window. High on-time delivery rates indicate reliability and customer satisfaction.

4. Perfect order rate: Measures the percentage of orders that are fulfilled accurately, on time, and without damage or defects. It provides insights into overall order accuracy, customer satisfaction, and part quality.

5. Supply chain cost-to-serve: Measures the total cost incurred to serve customers, including costs related to procurement, production, transportation, warehousing, and distribution. It helps identify areas for cost reduction and efficiency improvement.

6. Cash-to-cash cycle time: Measures the time it takes for cash to flow into the business from the sale of products to the time cash is paid out for raw materials or inventory. A shorter cash-to-cash cycle time indicates better working capital management and efficiency in the supply chain.

7. Supplier lead time: Measures the time it takes for suppliers to fulfill orders and deliver materials or components. Shorter supplier lead times reduce inventory holding costs and improve responsiveness to customer demand.

8. Optimizing by transportation cost per unit: Measures the cost of transporting goods per unit, taking into account factors such as distance, mode of transportation, and shipment size. Lower transportation costs per unit indicate more efficient transportation operations.

9. Establishing Return on Investment (ROI) of supply chain initiatives: Measures the financial return generated from investments in supply chain optimization projects or initiatives. It helps assess the effectiveness and impact of optimization efforts on overall business performance.

These metrics, among others, provide valuable insights into supply chain performance and help drive continuous improvement and optimization efforts to meet customer needs, reduce costs, and gain a competitive advantage in the marketplace.

Using the right software to manage data and metrics

Once the optimization plan is put together, it requires the right tools to handle the data and information to manage it properly. Many small and medium sized businesses tend to manage their supply chains in dedicated MRP systems, as mentioned above. 

For these businesses, Aligni MRP is built to handle the details involved in managing inventory demands for production as well as everything that goes into the purchasing and vendor management process.  It’s also designed to connect to all the relevant groups within an organization’s supply chain to make sure all have the up-to-date and correct information they need to execute effectively and efficiently. This combined approach means less digging through files, emails, and calling meetings to operate an effective strategy to manage inventory needs. That means more time managing the process instead of collecting information.

Bringing it all together

After touching on the intricacies of what goes into the supply chain optimization process, most understand there’s a lot to oversee between tracking the metrics and data, managing the relationships involved between departments and suppliers, and making sure all align with the company’s strategic goals. It’s easy to see why highly effective and efficient organizations turn to dedicated software to manage all the details and make it available for better decision making. 

If you’re looking to have more fine-grained control over everything that goes into the management of your supply chain, it’s time to step up to the right system to manage it all in one place, Aligni MRP.